Patent Description:
Work machines are commonly employed to carry out a plurality of different tasks on a worksite. Such work machines may include hauling machines, such as dump trucks, off-highway trucks, mining trucks, on-highway trucks or lorries/trucks, and articulated haulers, and earth-moving machines, such as backhoes, loaders, dozers, shovels, wheeled tractor scrapers, motor graders and excavators. The worksite may be, for example, a construction site, mine, quarry, waste dump site, aggregate site or the like. The work machines may be autonomously, semi-autonomously or manually operated to perform the tasks.

The work machines may be monitored by a monitoring system in order to determine their operating conditions and performance when performing the tasks. <CIT> discloses one such system in which a work machine comprises a plurality of sensors associated with the work machine for generating signals indicative of the operating conditions of the machine. The system is configured to determine the performance characteristics of the work machine based upon the signals and determine whether the work machine meets certain performance thresholds. However, using the sensors of <CIT> may be relatively expensive and complex and such an arrangement may have relatively high computational requirements.

<CIT> discloses a method and system for mapping terrain and operating autonomous machines using machine parameters. <CIT> discloses a system and method for monitoring a machine.

<CIT>, entitled "Systems and methods for improving haul route management," discloses a method for managing haul routes in work environments which comprises receiving performance criteria associated with a haul route and establishing a target total effective grade for at least one machine associated with the haul route based on the performance criteria. The method also includes collecting performance data associated with the at least one machine. The at least one machine is identified as an underperforming machine if the actual total effective grade for the at least one machine exceeds the target total effective grade. An average total effective grade for the at least one machine is determined as a function of the actual total effective grade. A haul route deficiency is identified if the average total effective grade exceeds a threshold level.

<CIT>, entitled "System and method for performance-based payload management," discloses a method for managing machine payload based on haul road conditions which comprises collecting performance data associated with a machine operating in a work environment and determining an actual total effective grade of the machine based on the collected performance data. The total effective grade is compared with a target total effective grade value, and total effective grade associated with a plurality of payload levels may be simulated if the actual total effective grade is not within a threshold range of the target total effective grade value. At least one of the plurality of payload levels that causes the simulated total effective grade to fall within the threshold range of the target total effective grade value is identified.

<NPL>" discloses a performance evaluation of a UAV system used to mobile 3D mapping data.

The present disclosure provides a method of monitoring the operation of at least one work machine according to claim <NUM>.

The present disclosure further provides a system for monitoring at least one work machine according to claim <NUM>.

The method comprises operating at least one work machine and/or generating an alert for an operator based upon the monitored operating condition data and optionally displaying the monitored operating condition data on a display.

The monitored operating condition data may be generated based upon at least one machine model and/or simulation algorithm. According to the invention, the at least one monitored operating condition comprises a monitored stress and/or strain magnitude and/or rate experienced by at least one machine structure as the at least one work machine moves along the route. The at least one work machine and/or at least one further work machine may be operated to remove or adjust the terrain event and/or below a machine speed limit. The machine speed limit may be determined based upon the monitored stress and/or strain magnitude and/or rate for the terrain event and the associated event threshold value.

The method may further comprise determining an expected lifetime of the at least one machine structure based upon the monitored operating condition data and a maximum lifetime stress and/or strain accumulation or rate associated with the at least one machine structure. The method may further comprise generating an alert indicative of at least one machine structure requiring repair and/or replacement, the alert being generated if the monitored stress and/or strain magnitude and/or rate meets a threshold magnitude and/or rate. The method may further comprise generating an alert indicative of a service schedule based upon the monitored stress and/or strain magnitude and/or rate. The method may further comprise: assigning a worksite duty segment to the worksite based upon the monitored stress and/or strain magnitude and/or rate meeting or falling within a range of magnitudes and/or rates of change of stress and/or strain associated with the worksite duty segment; and generating an alert indicative of the worksite duty segment; and/or generating an alert indicative of whether the at least one work machine is matched to the worksite duty segment based upon data associated with a plurality of work machines, a plurality of worksite duty segments and the suitability of each of the plurality of work machines to each of the plurality of worksite duty segments. The method may further comprise determining a warranty period of the at least one work machine based upon: the monitored operating condition data; the expected lifetime of at least one machine structure; a maximum accumulation of stress and/or strain on at least one machine structure; a maximum magnitude of stress and/or strain on at least one machine structure; and/or the worksite duty segment assigned to the worksite.

According to the invention, at least one terrain event is identified and at least one work machine is operated based upon the identified terrain event and/or an alert is generated. The at least one terrain event is identified at a location of the terrain where the monitored stress and/or strain magnitude and/or rate on at least one machine structure exceeds an event threshold value.

The at least one terrain event may be further identified at a location of the terrain where: at least one monitored operating condition exceeds an event threshold value; the rate of change of, or a summation of, simulated stress and/or strain rate exceeds an event threshold value; and/or the magnitude and/or rate of change of a gradient of the surface profile is above an event threshold value, the magnitude and/or rate of change of the gradient being determined by processing the actual surface profile data.

The method may further comprise operating at least one surveying device to re-measure at least part of the surface profile of the terrain and updating the actual surface profile data based upon the re-measurement. The machine model and/or simulation algorithm may comprise at least one structural parameter associated with at least one machine structure of the at least one work machine. Updating the machine model and/or simulation algorithm may comprise adjusting the at least one structural parameter such that the actual and simulated monitored operating condition data are the same or fall within a predetermined range of one another. The method may further comprise reprocessing the route data, machine operational data and actual surface profile data to generate simulated monitored operating condition data indicative of the at least one monitored operating condition of the at least one work machine moving along the route in accordance with the at least one operating parameter, the simulated monitored operating condition data being determined based upon the updated machine model and/or simulation algorithm.

The system may further comprise a computer system and/or a machine control system. The computer system may comprise the processing unit. The machine control system may be for controlling the operation of the at least one work machine. The computer system may be separate from or integrated with the machine control system. The at least one surveying device: may be separate from or integrated with the at least one work machine; may comprise at least one of a manned aircraft, an unmanned aerial vehicle and/or a manned or unmanned dedicated surface profile scanning vehicle; and/or may obtain the actual surface profile data via photogrammetry, radar, LIDAR, laser scanners, video systems and/or audio systems. The system may further comprise at least one work machine and a machine control system for controlling the operation of the at least one work machine.

The present disclosure is described in conjunction with the appended figures.

In the appended figures, similar components and/or features may have the same reference label.

The ensuing description provides preferred exemplary embodiment(s) only, and is not intended to limit the scope, applicability or configuration of the invention. Rather, the ensuing description of the preferred exemplary embodiment(s) will provide those skilled in the art with an enabling description for implementing a preferred exemplary embodiment of the invention, it being understood that various changes may be made in the function and arrangement of elements, including combinations of features from different embodiments, without departing from the scope of the invention as defined by the appended claims,.

Specific details are given in the following description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that embodiments may be practised without these specific details. For example, well-known circuits, processes, algorithms, structures, and techniques may be shown without unnecessary detail in order to avoid obscuring the embodiments.

Also, it is noted that the embodiments may be described as a process which is depicted as a flowchart, a flow diagram, a data flow diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. A process is terminated when its operations are completed, but could have additional steps not included in the figure. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination corresponds to a return of the function to the calling function or the main function. Moreover, as disclosed herein, the term "storage medium" may represent one or more devices for storing data, including read only memory (ROM), random access memory (RAM), magnetic RAM, core memory, magnetic disk storage mediums, optical storage mediums, flash memory devices and/or other machine readable mediums for storing information. The term "computer-readable medium" includes, but is not limited to portable or fixed storage devices, optical storage devices, wireless channels and various other mediums capable of storing, containing or carrying instruction(s) and/or data.

Furthermore, embodiments may be implemented by hardware, software, firmware, middleware, microcode, hardware description languages, or any combination thereof.

When implemented in software, firmware, middleware or microcode, the program code or code segments to perform the necessary tasks may be stored in a machine readable medium such as storage medium. A code segment may represent a procedure, a function, a subprogram, a program, a routine, a subroutine, a module, a software package, a class, or any combination of instructions, data structures, or program statements. A code segment may be coupled to another code segment or a hardware circuit by passing and/or receiving information, data, arguments, parameters, or memory contents. Information, arguments, parameters, data, etc. may be passed, forwarded, or transmitted via any suitable means including memory sharing, message passing, token passing, network transmission, etc..

It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact.

The present disclosure generally relates to a method and system for monitoring the operation of at least one work machine on a worksite. In particular, the system may comprise at least one surveying device for measuring the three-dimensional surface profile of the worksite. A computer system may receive data indicative of the surface profile and process the data to perform a simulation of the work machine manoeuvring over the worksite. The system may also comprise a work machine control system configured to monitor at least one operating parameter related to the operation of the work machine. The computer system may receive data relating to the at least one operating parameter and perform the simulation in accordance with the at least one operating parameter. The simulation may be used to monitor at least one operating condition of the work machine other than the at least one operating parameter. Thus the method and system differ from <CIT>, which does not provide for using predictive modelling and/or use of measured data in such predictive modelling.

<FIG> illustrates an embodiment of a system <NUM> of the present disclosure comprising at least one work machine <NUM> moving along a route <NUM> over a terrain <NUM> of a worksite <NUM>. The system <NUM> may further comprise at least one surveying device <NUM> for measuring the three-dimensional surface profile of the worksite <NUM>. The at least one surveying device <NUM> and at least one work machine <NUM> may be configured to communicate and/or transfer data with a computer system <NUM> via a communication system <NUM>.

The worksite <NUM> may comprise an area within which earth or other material is moved and/or manipulated and may be an off-road area. The illustrated worksite <NUM> is a mine, although in other embodiments the worksite <NUM> may comprise a construction site, an open or closed mine, quarry, waste dump site, aggregate site or the like. The terrain <NUM> may comprise the ground of the worksite <NUM> over which the work machine <NUM> travels and the route <NUM> may comprise the path of the work machine <NUM> over the terrain <NUM>. The route <NUM> may comprise a path from a first location to a second location.

The at least one work machine <NUM> may be any type of work machine <NUM> suitable for the worksite <NUM> and the system <NUM> may comprise a plurality of the same or different work machines <NUM>. The illustrated work machine <NUM> is an articulated hauler, although in other embodiments the work machine(s) <NUM> may comprise hauling machines, such as dump trucks, on-highway trucks or lorries and off-highway trucks, and/or earth-moving or material handling machines, such as backhoes, wheel tractor scrapers, loaders, dozers, shovels, drilling machines, motor graders, forestry machines and excavators.

According to the invention, the at least one work machine <NUM> comprises at least one machine structure, which may refer to any physical component, system and/or sub-system of the work machine <NUM>, such as the frames, chassis, ground engaging members (e.g. wheels or tracks), suspension systems (e.g. suspension springs, beams, hydraulic cylinders, connections, axles and the like), engine components (e.g. fuel injectors, valves, cylinders, crankshaft, cooling system, turbochargers, superchargers, batteries, electrical systems and the like), powertrain (e.g. transmissions, torque converters, shafts, differentials and the like), the at least one work tool <NUM> (e.g. dump bodies, buckets, hydraulic systems, electrical systems and the like), rigid and flexible linkages and the like. In particular, the at least one work machine <NUM> may comprise an engine system configured to drive at least one ground engaging arrangement to move the at least one work machine <NUM> along the route <NUM>. The at least one ground engagement member may comprise at least one wheel, tracks or the like. The engine system may comprise at least one power unit (e.g. a internal combustion engine, electric motor and/or hydraulic motor) configured to drive a powertrain. The powertrain may comprise at least one transmission configured to drive at least one output shaft or the like for driving the at least one ground engagement member.

The work machine <NUM> may comprise at least one work tool <NUM> for performing work on the worksite <NUM>. The form of the at least one work tool <NUM> may depend upon the type of the work machine <NUM>. In the case of a hauling machine the at least one work tool <NUM> may comprise a dump body or other arrangement for holding bulk material during transportation. The dump body may be pivotable to allow ejection of the material or may comprise an actuatable ejector member within the dump body to enable ejection of the material. In the case of an earth-moving or material handling machine, the at least one work tool <NUM> may be of any suitable type for digging, lifting or otherwise manipulating material of the worksite <NUM>, such as a bucket, shovel, conveyor or the like.

If the work machine <NUM> comprises a hauling machine the first location may be a location on the worksite <NUM> at which the hauling machine is loaded with material and the second location may be a location on the worksite <NUM> at which the hauling machine ejects the material. The route <NUM> may therefore be a "haul route" and the at least one work machine <NUM> may travel over the haul route 12a plurality of times in order to transfer a plurality of loads of material between the first and second locations. If the work machine <NUM> comprises an earth-moving or material handling machine the first location may be the location at which the work machine <NUM> picks up material from the terrain <NUM> and the second location may be the location at which the earth-moving machine deposits the material into a hauling machine. A haul route may be a route <NUM> between at least one loading location and at least one ejection location. Alternatively, the material handling machine may also travel along the haul route, for example between a first location, at which the material handling may be parked or stored when not in use, and a second location, where the material handling machine may perform work. In the present disclosure two routes <NUM> may be considered to be the same if they are within a threshold distance of one another or both routes <NUM> fall within a boundary of one another. Such a threshold distance and/or boundary may be preset and may be stored in the computer system <NUM>. For example, the threshold distance and/or boundary may be less than approximately <NUM> meters, less than approximately <NUM> meters, less than approximately <NUM> meters, less than approximately <NUM> meters and/or less than approximately <NUM> meter.

The work machine <NUM> may comprise a machine control system <NUM> as schematically illustrated in <FIG>. The machine control system <NUM> may comprise a controller <NUM> communicatively connected (via a wired or wireless connection) to at least one input <NUM>, at least one output <NUM>, at least one sensor <NUM> and at least one machine communication module <NUM>. The controller <NUM> may be of any suitable known type and may comprise an engine control unit (ECU) or the like. The controller <NUM> may comprise a memory <NUM>, which may store instructions or algorithms in the form of data, and a processing unit <NUM>, which may be configured to perform operations based upon the instructions. The memory <NUM> may comprise any suitable computer-accessible or non-transitory storage medium for storing computer program instructions, such as RAM, SDRAM, DDR SDRAM, RDRAM, SRAM, ROM, magnetic media, optical media and the like. The processing unit <NUM> may comprise any suitable processor capable of executing memory-stored instructions, such as a microprocessor, uniprocessor, a multiprocessor and the like. The controller <NUM> may further comprise a graphics processing unit for rendering objects for viewing on a display. The controller <NUM> may receive data from at least one input <NUM>, at least one sensor <NUM> and/or the machine communication module <NUM> and perform operations based upon the instructions, such as by sending data to an output <NUM>, at least one sensor <NUM> and/or the machine communication module <NUM>, performing calculations or carrying out logic-based tasks.

The machine communication module <NUM>, discussed in further detail below, may be configured to transfer data between the machine control system <NUM> and the communication system <NUM>, computer system <NUM>, surveying device <NUM> and/or another machine control system <NUM> of another work machine <NUM>.

The at least one input <NUM> may comprise a device for operation by, or receiving at least one input from, an operator for controlling the work machine <NUM>, such as a gear selector, a steering wheel, a brake pedal, a speed selector (e.g. an accelerator pedal), a work tool manipulator (e.g. a joystick), a dashboard button and the like. The at least one input <NUM> may define at least one operating condition according to which the at least one work machine <NUM> is operated. The at least one input <NUM> may relate to, for example, a gear selection, movement of the steering wheel, a braking command, a speed command, a work tool <NUM> manipulation, a button press or the like.

The at least one output <NUM> may comprise a device for operating the machine in accordance with the at least one input <NUM>. The at least one output <NUM> may be operated under at least one operating condition, which may result due to the at least one operating condition of the at least one input <NUM>. Exemplary outputs <NUM> include the transmission, the engine or any part thereof, a valve system, a fuel injection system, an electric, pneumatic and/or hydraulic system for controlling the work machine <NUM> and/or at least one work tool <NUM> (particularly a dump body, ejector body or conveyor), a steering mechanism, brake actuators, a differential lock, a display for displaying information to an operator, lights and the like. The at least one operating condition implemented by the at least one output <NUM> may be any type of operating condition of the work machine <NUM>, such as, for example, a machine speed, a direction of travel, an engine speed, a powertrain load, a braking or retarding load, gear selection or transmission ratio, work tool <NUM> positioning, work tool <NUM> manipulation (e.g. opening or closing shears, a bucket and the like), a payload measurement (e.g. the load caused by material in a dump body , bucket or the like), fluid pressure in hydraulic circuits (e.g. for controlling the work tool <NUM>), electric current or voltage levels and the like.

The at least one sensor <NUM> may comprise any device configured to determine and monitor at least one actual operating condition of the work machine <NUM> and generate actual machine operational data indicative of the at least one actual operating condition. The at least one actual operating condition may comprise at least one operating condition as described above or indicative of the state of the work machine <NUM> or a component, system or subsystem thereof. For example, the at least one sensor <NUM> may be configured to sense operation of at least one input <NUM> or the effect of the operation of at least one output <NUM>.

The at least one sensor <NUM> may be configured to determine the at least one operating condition of at least one machine structure of the work machine <NUM>. The at least one sensor <NUM> may comprise a strain sensor for determining the stress and/or strain on a machine structure (e.g. the stresses experienced by a beam of a suspension system), a load sensor for determining the load upon a machine structure (e.g. a sensor positioned to determine the payload in a dump body), a temperature sensor for determining the temperature of a machine structure (e.g. the temperature of hydraulic fluid or brakes), a speed sensor for determining the speed/velocity of a machine structure (e.g. an engine output speed sensor for detecting the rotational velocity of at least one output shaft from the engine), an inclination sensor for determining the three-dimensional inclination of the at least one work machine <NUM> on the terrain <NUM> and generating inclination data indicative of the inclination, a position sensor for determining the position of a machine structure (e.g. the position of parts of the at least one work tool <NUM>), an accelerometer for measuring the acceleration experienced by at least one machine structure and/or the at least one work machine <NUM> due to vibrations and/or a load, and the like. In particular, at least one accelerometer may be arranged to measure the load input to at least one ground engaging means.

The at least one sensor <NUM> may comprise a dump body monitor for determining the status of the dump body, if present on the at least one work machine <NUM>. In particular, the dump body monitor may comprise an inclination sensor for measuring the inclination of a pivotable dump body, a position sensor for determining the position of an ejector member of a dump body with an ejector and/or a load sensor for determining the load of material, if any, in the dump body.

The system <NUM> may further comprise a navigation system for determining the position of the at least one work machine <NUM> and generating actual route data indicative of its position on the worksite <NUM>. The navigation system may determine the location of the at least one work machine <NUM> on the Earth's surface and/or may determine the location of the at least one work machine <NUM> relative to a reference position on the worksite <NUM>. The actual route data may comprise the position of the work machine <NUM> in two dimensional coordinates X, Y representing its position on a plane parallel to the surface of the worksite <NUM>. The actual route data may also comprise a third dimensional coordinate Z indicative of the "height" of the machine relative to a reference height. The actual route data may comprise a plurality of coordinates indicating the position of the at least one work machine <NUM> as it moves over the terrain <NUM> and the plurality of coordinates may define the route <NUM>. The plurality of coordinates may be generated by sampling the position of the at least one work machine <NUM> at time intervals.

The navigation system may comprise any suitable navigation system. In particular, the at least one sensor <NUM> may comprise a position sensor operable to determine the position of the work machine <NUM> via a global navigation satellite system, such as global positioning system (GPS), or via triangulation with communication masts. Alternatively, the navigation system may be embodied in the machine control system <NUM>, which may substantially continuously monitor at least the speed and direction of the work machine <NUM> as it moves over the worksite <NUM> between a first and second location. The coordinates of the first location may be input into the machine control system <NUM> and stored on the memory. Based upon the monitored speed and direction of the work machine <NUM> the machine control system <NUM> may be operable to determine the coordinates of the second location.

The at least one surveying device <NUM> may be configured to measure the three-dimensional surface profile or topography of the terrain <NUM> of the worksite <NUM> and generate actual surface profile data indicative of the actual surface profile. In particular, the at least one surveying device <NUM> may be configured to generate actual surface profile data in the form of a point cloud of the terrain <NUM>. The actual surface profile data may be processed, such as by extrapolation between points of a point cloud, to create a "virtual map" and/or to perform further operations, as discussed below. The at least one surveying device <NUM> may utilise any method, sensor, instrumentation or other apparatus known in the art to obtain the actual surface profile data, such as photogrammetry, radar, LIDAR, laser scanners, video systems, audio systems or a combination thereof.

The at least one surveying device <NUM> may comprise a device separate from the at least one work machine <NUM>. The at least one surveying device <NUM> may comprise a surveying device communication module configured to communicate with, and send the actual surface profile data to, the at least one work machine <NUM>, computer system <NUM> and/or communication system <NUM>. The at least one surveying device <NUM> may comprise an aerial platform, such as a manned aircraft or unmanned aerial vehicle ("UAV"), or a terrestrial (i.e. land based) platform, such as a dedicated surface profile scanning vehicle (manned or unmanned).

Alternatively, the at least one surveying device <NUM> may be partly or entirely embodied in the at least one work machine <NUM>. For example, the at least one sensor <NUM> may comprise instrumentation for generating the actual surface profile data as the at least one work machine <NUM> moves over the worksite <NUM>. The instrumentation may operate according to any suitable surface profiling method, such as video, laser scanning, imaging and the like.

The system <NUM> may comprise a plurality of surveying devices <NUM>, which may be of different types and use different surveying methods. In particular, at least one surveying device <NUM> may comprise a UAV comprising a photogrammetric system and at least one surveying device <NUM> may be a LIDAR system located on at least one work machine <NUM>. The UAV may generate initial actual surface profile data which may be updated with actual surface profile data from the LIDAR system as the work machine <NUM> moves material and alters the surface profile of the terrain <NUM>.

The actual surface profile data collected by the at least one surveying device <NUM> may comprise at least one reference position associated with it such that the actual route data and actual surface profile data may be referenced to one another. For example, the actual surface profile data and actual route data may comprise at least one coordinate in the form of a geographic latitude and longitude of the Earth's surface. As a result, the actual route data may be accurately mapped to a location on the actual surface profile data such that the position of the work machine <NUM> on the worksite <NUM> may be determined. The at least one surveying device <NUM> may utilise the navigation system and/or other positioning system for determining the position of the at least one surveying device <NUM> as it gathers the actual surface profile data such that the at least one reference position can be determined.

The computer system <NUM> may be configured to receive actual surface profile data, actual machine operating condition data and/or the actual route data and perform simulations of the operation of the at least one work machine <NUM>. The computer system <NUM> may be separate from the work machine <NUM> and at least one surveying device <NUM> as illustrated (e.g. by being located in a separate housing) and they may communicate data within one another via the communication system <NUM>. The computer system <NUM> may be located in a monitoring station on the worksite <NUM> or at a station remote to the worksite <NUM>. For example, the computer system <NUM> may be located in a central server and database of the operating company of the worksite <NUM>, the at least one surveying device <NUM> and/or the at least one work machine <NUM>. Alternatively, the computer system <NUM> may be located on the at least one work machine <NUM> (separately or integrally with the machine control system <NUM>) and/or the at least one surveying device <NUM>. In particular, the computer system <NUM> as described herein may be embodied as the machine control system <NUM>. Thus any references herein to the performance of a method or operation on the computer system <NUM> may also be considered to be references to the performance of a method or operating on the machine control system <NUM> and vice-versa.

The computer system <NUM> may comprise any known computer system <NUM>, such as a personal computer, laptop, tablet computer, server, smartphone and the like. In particular, the computer system <NUM> may comprise a memory storing instructions or algorithms as memory data and a processing unit, which may be configured to perform operations based upon the instructions. The memory may comprise any suitable computer-accessible or non-transitory storage medium for storing computer program instructions, such as RAM, SDRAM, DDR SDRAM, RDRAM, SRAM, ROM, magnetic media, optical media and the like. The processing unit may comprise any suitable processor capable of executing memory-stored instructions, such as a microprocessor, uniprocessor, a multiprocessor and the like. The computer system <NUM> may comprise a plurality of input and/or output devices for providing an input to, or receiving an output from, the processing unit. Exemplary input and output devices include displays, keyboards, mice, joysticks, touch screens, buttons, external network interfaces for transferring information to and/or from an external network such as the Internet, other communication ports (e.g. universal serial bus ports), speakers, lights and the like. The computer system <NUM> may further comprise a graphics processing unit for rendering objects for viewing on a display. The computer system <NUM> may comprise a computer system communication module for communication with the at least one work machine <NUM>, at least one surveying device <NUM> and/or the communication system <NUM>.

The computer system <NUM> may comprise data, instructions or algorithms stored on the memory, for example in a database, related to a machine simulator, which may be processed by the processing unit to simulate the operation of the at least one work machine <NUM> in accordance with at least one operating parameter. In the present disclosure the term "operating parameter" may refer to an actual or simulated operating condition according to which the work machine <NUM> is simulated in the machine simulator. In the present disclosure "simulate" may refer to elements (e.g. routes, parameters etc) involved in producing and running a computer model, whereas "actual" may refer to the elements involved in actually operating at least one work machine <NUM>. The machine simulator may be configured to construct a virtual model of the at least one work machine <NUM>, simulate the operation of the at least one work machine <NUM> in accordance with at least one operating parameter and analyse the operating conditions of the at least one work machine <NUM> during the simulated operation. The machine simulator may comprise a multibody system dynamics simulator and suitable machine simulator software for performing the machine simulation on the computer system <NUM> may include any multibody dynamics simulation software.

The data, instructions or algorithms related to the machine simulator stored on the memory may be related to at least one of:.

The communication system <NUM> may be configured to enable communication between the machine control system(s) <NUM> of the at least one work machine <NUM>, the at least one surveying device <NUM>, the computer system <NUM> and/or another machine control system <NUM> of another work machine <NUM>. The communication system <NUM> and associated machine, computer system and surveying device communication modules <NUM> may comprise any type suitable apparatus for communication therebetween, particularly a wireless or wired network. Exemplary wireless networks include a satellite communication network, broadband communication network, cellular, Bluetooth, microwave, point-to-point wireless, point-to-multipoint wireless, multipoint-to-multipoint wireless, Wireless Local Service (WiFi Dongle), Dedicated Short-Range Communications (DSRC) or any other wireless communication network. Exemplary wired networks include Ethernet, fibre optic, waveguide or any other suitable wired connection.

As discussed above, the at least one work machine <NUM> may comprise the computer system <NUM> and/or the at least one surveying device <NUM>, which may form part of the machine control system <NUM>. Therefore, the system <NUM> may not comprise the communication system <NUM> or the communication system <NUM> may be embodied as connections between the aforementioned components of the machine control system <NUM>.

An exemplary method <NUM> of operating the system <NUM> is illustrated in <FIG>. The method <NUM> may comprise at least one surface profile generating step <NUM>, machine position generating step <NUM>, operating parameter generating step <NUM>, machine model retrieval step <NUM>, simulation step <NUM> and analysis step <NUM>.

In the surface profile generating step <NUM> actual and/or simulated surface profile data may be generated. At least one surveying device <NUM> may travel over the worksite <NUM>, measure the topography of the terrain <NUM> with reference to at least one reference location on the worksite <NUM> and generate point cloud data indicative of the actual three-dimensional surface profile of the worksite <NUM>. Therefore, actual surface profile data may be generated. The actual surface profile data may be communicated to the work machine <NUM> and/or computer system <NUM>, for example via the communication system <NUM>. The at least one surveying device <NUM> may measure at least the topography of the route <NUM>, which may be a predetermined route <NUM> for movement of at least one work machine between first and second locations. However, instead, the at least one surveying device <NUM> may measure the topography of the entire terrain <NUM> rather than just a certain route <NUM>. For example, the worksite <NUM> may be defined as being within boundaries, for example having a polygonal shape. The boundaries may include a plurality of haul routes located within them. The at least one surveying device <NUM> may be controlled to travel between the boundaries to generate point cloud data indicative of the entire surface profile in the worksite <NUM>.

Alternatively, the surface profile generating step <NUM> may comprise generating simulated surface profile data and/or retrieving previously generated simulated surface profile data from a memory, such as the memory of the computer system <NUM> or machine control system <NUM>. The simulated surface profile data may be randomly generated, operator generated (e.g. explicitly specified by an operator) or may be based upon actual surface profile data from a historical worksite <NUM>. The memory may store simulated surface profile data from a plurality of worksites <NUM>.

In the machine position generating step <NUM> actual and/or simulated route data may be generated. In particular, the navigation system may determine actual coordinates indicative of the position of the work machine <NUM> as it moves along the route <NUM> and generate actual route data indicative of the actual route <NUM>. Alternatively, the route <NUM> of the machine may be simulated by generating simulated route data and/or retrieving previously generated actual or simulated route data indicative of a simulated route <NUM>. For example, an operator may explicitly define a route <NUM> of the work machine <NUM> over the terrain <NUM>. Alternatively, the computer system <NUM> may determine an optimal path of the work machine <NUM> over the terrain utilising the surface profile data, as discussed in further detail below.

In the operating parameter generating step <NUM> actual and/or simulated machine operational data may be generated and may comprise data associated with at least one operating parameter of the machine simulator. The actual and/or simulated machine operational data may comprise a single value of at least one operating parameter or a variation of the at least one operating parameter along the route <NUM> and/or in relation to a time period.

The machine control system <NUM> may determine at least one operating condition, which may be any of the operating conditions described above, of the work machine <NUM> as it actually moves along the route <NUM> and generate actual machine operational data. The machine control system <NUM> may monitor at least one input <NUM> indicative of the actual inputs received from an operator, such as throttle position, gear selection, steering wheel or joystick manipulation, brake pedal application, retarder application and the like. Thus the machine operational data may comprise actual machine operational data indicative of actual operator inputs. The machine control system <NUM> may monitor the at least one output <NUM> indicative of the actual outputs resulting from at least one input <NUM> from an operator. For example, the machine control system <NUM> may monitor engine speed, machine speed (i.e. the actual speed of the at least one machine <NUM> moving over the terrain <NUM>), gear selection, direction of travel or the route <NUM>, a differential lock engagement and the like. The machine control system <NUM> may monitor both at least one input <NUM> and at least one output <NUM> in order to account for both operator control and automatic control of the at least one output <NUM>. Alternatively, the actual machine operational data may be determined from the data received from the at least one sensor.

Simulated machine operational data may be determined by the computer system <NUM> generating at least one simulated operating condition and/or by retrieving previous generated simulated machine operational data from a memory. The at least one simulated operating condition may be specified by an operator (i.e. a human). The computer system <NUM> may store simulated machine operational data indicative of at least one optimal operating condition of the work machine <NUM>. The optimal operating condition of the work machine <NUM> may be associated with known surface profiles and/or ranges and/or values of inclinations of terrain.

The computer system <NUM> may store an optimal operating condition database on its memory containing optimal operating conditions associated with a plurality of known surface profiles and routes <NUM>. The computer system <NUM> may process the actual surface profile data of the route <NUM> to determine the closest known surface profile to the actual surface profile. The simulated operating condition for the known surface profile may subsequently be retrieved from the optimal operating condition database and utilised in the simulated machine operational data. For example, simulated machine operational data indicative of the machine speed may be selected based upon the inclination of the work machine <NUM> on the route <NUM> such that the machine speed is at a safe level for the inclination. The computer system <NUM> may break the actual surface profile and known surface profile into portions such that a plurality of known surface profiles may be accorded to the actual surface profile. Therefore, the simulated machine operational data may comprise a variation of the at least one simulated operating parameter along the route to match it to the optimal operating condition for each portion of the actual surface profile.

The computer system <NUM> may store a look-up table of at least one optimal operating condition associated with a value and/or range of inclinations of the terrain <NUM>. The computer system <NUM> may process the actual surface profile data and route <NUM> therealong to determine the inclination of the terrain <NUM> along the route <NUM>. The computer system <NUM> may retrieve data from the look-up table to assign at least one optimal operating condition to the inclination of the terrain <NUM>. The at least one optimal operating condition assigned may vary along the route <NUM> to match variations in the inclination.

Furthermore, the simulated machine operational data may be selected based upon actual machine operational data in order to ensure that if at least one actual operating condition is measured, all of the rest of the operating parameters required for the machine simulator to perform the simulation may be obtained. As discussed above, the machine model and/or simulation algorithm may require a plurality of operating parameters. If actual machine operational data is not provided for all of the required operating parameters, the computer system <NUM> may retrieve or determine simulation operational data for the rest of the required operating parameters. For example, if the actual machine speed is used but there is no measurement of actual payload of the work machine <NUM>, an estimated or average payload may be retrieved from a memory and incorporated into the simulated machine operational data.

In the machine model retrieval step <NUM> the at least one work machine <NUM> type may be identified and a machine model representative of the at least one work machine <NUM> retrieved from the memory. In particular, identification data may be transmitted from the at least one work machine <NUM> to the computer system <NUM> such that the computer system <NUM> may retrieve the appropriate machine model. During the machine model retrieval step <NUM> model parameter may also be retrieved, although it may be integral with the machine model.

At a simulation step <NUM> the computer system <NUM> may receive the simulated or actual surface profile, machine position and operating condition data and implement the simulation algorithm and machine model based upon the at least one structural parameter. In particular, the computer system <NUM> may simulate the operation of the at least one work machine <NUM> as it moves along the route <NUM> over the actual or simulated surface profile in accordance with the at least one actual or simulated operating parameter. During the simulation monitored operating condition data may be generated, which may be indicative of at least one monitored operating condition of at least one machine structure of the at least one work machine <NUM>. The at least one monitored operating condition may be different to the at least one operating parameter and may be monitored based upon the machine model of the at least one work machine <NUM>. The machine model may be configured to enable calculations to be performed to generate monitored operating condition data indicative of the effect on the at least one monitored operating condition of the simulated or actual surface profile, machine position and operating condition data and the at least one structural parameter.

At an analysis step <NUM> the monitored operating condition data may be processed in order to analyse the behaviour of the work machine <NUM> as it travels along the route <NUM>. At least one type of analysis, as described below, may be carried out. The results of the analysis step <NUM> may be displayed to an operator on a display, such as in the form of at least one plot, gauge, map or table.

In a structural analysis the stress and/or strain imposed on at least one machine structure during the simulation may be monitored. For example, FEA, flexible body and/or multibody analysis of the at least one machine structure may be performed utilising the simulation algorithm and machine model. The structural analysis may be continuously performed and/or discretely performed and extrapolated in order to determine the stress and/or strain imposed on at least one machine structure as the work machine <NUM> moves along the route <NUM>. The resulting structural analysis data generated may be presented to an operator on the display as a graph (for example with stress and/or strain on the Y axis and distance along the route on the X axis) and/or utilised by the computer system <NUM> to perform further tasks. The structural analysis data may therefore represent a substantially similar output to a strain sensor located on the at least one actual machine structure.

In a stress and/or strain rate analysis the computer system <NUM> may calculate the stress and/or strain imposed upon at least one machine structure over a time period. For example, the computer system <NUM> may be operable to determine an average stress and/or strain over a time period. Alternatively, the stress and/or strain rate may be calculated by determining the maximum stress and/or strain over a short time period and then averaging the maximum stress and/or strain of a plurality of short time periods constituting a longer time period.

In a structure lifespan analysis the computer system <NUM> may calculate the expected lifetime of at least one machine structure. The expected lifetime may be a time period and may be based upon the stress and/or strain rate upon the at least one machine structure (e.g. the average stress and/or strain rate of the at least one machine structure) and a maximum lifetime stress and/or strain accumulation or rate associated with the at least one machine structure. In the structure lifespan analysis the computer system <NUM> may also determine whether the at least one machine structure has reached the expected lifetime. The maximum lifetime stress and/or strain may be a value and/or range and may be stored on the memory of the computer system <NUM>. The maximum lifetime stress and/or strain may be defined by an operator and may be associated with a total stress and/or strain experienced by the at least one machine structure at which the at least one machine structure is expected to fail. The maximum lifetime stress and/or strain may account for a safety factor.

In a maintenance analysis the computer system <NUM> may utilise the structural analysis, the structure lifespan analysis and/or the stress and/or strain rate analysis to determine when at least one machine structure needs to be replaced and/or repaired. Based upon the determination the computer system <NUM> may issue an alert to an operator that at least one machine structure needs to be replaced and/or repaired. The computer system <NUM> may determine that at least one machine structure needs to be replaced and/or repaired if a structural and/or stress and/or strain rate analysis indicates that during operation of the at least one work machine <NUM> the stress and/or strain exceeded a threshold magnitude, total and/or rate. The threshold magnitude, total or rate may be associated with a single instance of a stress and/or strain magnitude (e.g. a sudden spike in stress on a machine structure), summation of stress and/or strain over time or a rate of change of a stress and/or strain at which the integrity of the at least one machine structure may be compromised, such as by reaching or approaching a yield point (e.g. a magnitude at which cracks are likely to form or failure might occur). The computer system <NUM> may determine that at least one machine structure needs to be replaced and/or repaired if a structure lifespan analysis indicates that the at least one machine structure has reached, or is reaching, its calculated expected lifetime.

In the maintenance analysis the computer system <NUM> may also determine a suitable time (e.g. a date or date range) at which to schedule a service or overhaul of the at least one work machine <NUM>. In the present disclosure "service" or "overhaul" may relate to periodic general maintenance of the at least one work machine <NUM>. The maintenance analysis may set the service or overhaul date based upon the shortest structure lifespan of any of those calculated in the structure lifespan analysis. The service or overhaul date may also be set based upon weather and/or corrosive limits associated with at least one machine structure.

In a worksite duty analysis the computer system <NUM> may assign a worksite duty segment to the at least one worksite <NUM> and/or may assess the suitability of operating at least one work machine <NUM> on at least one worksite <NUM>. The computer system <NUM> may store data related to a plurality of worksite duty segments, such as a light duty segment, at least one medium duty segment or a heavy duty segment. The computer system <NUM> may also associate each worksite duty segment with a range of values associated with any of the analyses discussed herein. The computer system <NUM> may associate a worksite duty segment with a range of magnitudes and/or rates of change of stress and/or strain on at least one machine structure of at least one work machine <NUM>. The low duty segment may be associated with a range below a first duty threshold and the high duty segment may be associated with a range above the first or a second duty threshold, the second duty threshold being above the first duty threshold. The at least one medium duty segment may define one or more ranges between the first and second duty thresholds.

The computer system <NUM> may assign a worksite duty segment to the at least one worksite <NUM> based upon the stress and/or strain rate analysis and/or the structural analysis. A worksite duty segment may assigned based upon the monitored stress and/or strain magnitude and/or rate meeting or falling within the range of magnitudes and/or rates of change of stress and/or strain associated with the worksite duty segment.

The computer system <NUM> may store data associated with a plurality of work machines <NUM>, a plurality of worksite duty segments and the suitability of each of the plurality of work machines <NUM> to each of the plurality of worksite duty segments. The computer system <NUM> may also assess the suitability of the at least one work machine <NUM> to the worksite <NUM> based upon the stress and/or strain rate analysis and/or the structural analysis on at least one work machine <NUM>. If the at least one work machine <NUM> is not suitable for the worksite duty segment associated with the worksite <NUM>, the computer system <NUM> may generate an alert to an operator and may propose at least one different work machine <NUM> that is more suitable for the worksite duty segment.

The computer system <NUM> may be configured to run the machine simulator to simulate a plurality of work machines <NUM> travelling along a simulated route <NUM> in accordance with at least one simulated operating parameter and thereby generate monitored operating condition data for each work machine <NUM>. Based upon which worksite duty segment the monitored operating condition data is associated with, and the data associating at least one work machine <NUM> to a worksite duty segment, the computer system <NUM> may determine a suitable type of work machine <NUM> for the worksite <NUM>.

In a warranty analysis the computer system <NUM> may determine a warranty period based upon any of the analyses discussed herein. Therefore, the system <NUM> may be utilised to specify variable warranties of the at least one work machine <NUM>. A "warranty" may be considered in the present disclosure to be a guarantee, issued to the operator of the at least one work machine <NUM> by its manufacturer and/or seller, promising to repair or replace the at least one work machine <NUM> and/or a part thereof if necessary within a specified "warranty period", which may be a time warranty period. The warranty period may be associated with at least one machine structure lifespan calculated in the structure lifespan analysis. A warranty period may be specified based upon a maximum accumulation of stress and/or strain on at least one machine structure rather than an actual time period. Alternatively, a warranty period may be specified based upon a maximum magnitude of stress and/or strain on at least one machine structure. The warranty period may be specified based upon the worksite duty analysis. As a result, if an operator operates the at least one work machine <NUM> under very heavy duty conditions (e.g. a short structure lifespan, a heavy duty worksite and/or reaching a maximum summation of stress and/or strain) the warranty may be reduced or cancelled accordingly. The warranty period may be based upon actual machine operational data indicative of undesired operating parameters of the at least one work machine <NUM>. For example, the warranty period may be reduced if a retarder is not utilised and/or service brakes are only utilised, or if at least one work machine <NUM> is operated down a grade out of gear (i.e. in neutral) rather than in gear.

In a terrain analysis the computer system <NUM> may identify terrain events associated with the terrain <NUM>. The computer system <NUM> may determine the location of at least one terrain event based upon the actual or simulated route data, actual or simulated surface profile data, actual or simulated machine operational data and/or the monitored operating condition data. In particular, the terrain event may be identified at a location on the terrain <NUM> where at least one monitored operating condition exceeds an event threshold value. The memory of the computer system <NUM> may store a plurality of event threshold values associated with different terrain events.

The computer system <NUM> may utilise data obtained via the stress and/or strain rate analysis and/or the structural analysis and may identify a terrain event associated with the roughness of the terrain <NUM>. In the present disclosure "roughness" may refer to the size of variations, irregularities or bumps of the surface of the terrain <NUM>. A relatively high roughness may indicate a heavy duty worksite <NUM> (e.g. having a very rocky terrain <NUM>) and a relatively low roughness may indicate a low duty worksite <NUM> (e.g. having a very smooth terrain <NUM>). According to the invention, a terrain event is identified where the monitored stress and/or strain magnitude and/or rate on at least one machine structure exceeds an event threshold value. A terrain event may also be identified over a region of the terrain <NUM> in which the rate of change of, or a summation of, simulated stress and/or strain rate exceeds an event threshold value. Such terrain events may therefore indicate a location of the terrain <NUM> imposing a relatively high stress and/or strain on the at least one machine structure and thus at least one work machine <NUM>.

A terrain event may also be determined from the surface profile data. A terrain event may be associated with a gradient of the terrain <NUM> and a terrain event may be identified by processing the surface profile data to identify where the magnitude and/or rate of change of the gradient is above an event threshold value. A terrain event may be associated with at least one obstacle (such as a building, other work machine <NUM>, impassable terrain or the like), which may be identified by processing the surface profile data or by an operator associating the location of such obstacles with the surface profile data. A terrain event may be a location at which ejection from an articulated hauler is not suitable by virtue of tip-over being likely at the terrain event due to a high gradient.

In the terrain analysis the computer system <NUM> may identify at least one terrain event and perform further operations based upon the identification. The computer system <NUM> may identify at least one terrain event associated with the route <NUM> and propose a new route <NUM> for the at least one work machine <NUM> to follow. For example, the computer system <NUM> may identify an area of relatively rough terrain <NUM>, steep gradient and/or obstacle and adjust the route <NUM> to avoid the relatively rough terrain <NUM>, steep gradient and/or obstacle. Alternatively, the computer system <NUM> may identify at least one terrain event based upon operating the machine simulator based upon actual surface profile data, simulated route data and simulated machine operating condition data.

A terrain event may be identified by assessing the point cloud data of the actual surface profile data. The terrain event may, for example, be a bump, pot hole, ditch, rock, cliff or the like. The point cloud data may be processed to identify variation of a predetermined percentage of adjacent points by a preset distance and associate the variation with the terrain event. For example a variation of <NUM>% of adjacent points by at least <NUM>, relative to surrounding points, may indicate the presence of a pot hole.

The computer system <NUM> may generate an optimal route <NUM> by running the machine simulator for a plurality of different routes <NUM> until the route <NUM> with the lowest number, if any, of terrain events is identified and proposing that route <NUM> as the optimal route <NUM>. The optimal route <NUM> may also be selected based upon the machine productivity along the route <NUM>. The optimal route <NUM> may be determined utilising any analytical method known in the art, such as a neural network algorithm or the like. In particular, the analytical method may comprise assessing a plurality of routes <NUM> across the terrain <NUM> between first and second locations. The plurality of routes <NUM> may be stored on a database and may be specified by an operator. The computer system <NUM> may determine the efficiency of each of the plurality of routes <NUM>, for example based upon efficiency data associated with monitored operating condition data. The efficiency data may be fuel efficiency, stress and/or strain, efficient machine speed and the like of the at least one machine <NUM>. The optimal route <NUM> may be the route <NUM> with the optimal efficiency. The plurality of routes <NUM> may be segmented between first and second locations and each segment assessed individually. In a particular example, a plurality of routes <NUM> may be segmented. The stress and/or strain on at least one machine structure when travelling across each segment may be assessed. The optimal route <NUM> may be the route <NUM> comprising the segments having the lowest total summation of stress and/or strain on the at least one machine structure.

According to the invention, the computer system <NUM> identifies at least one terrain event and issue an alert to an operator and/or the at least one work machine <NUM> is operated based upon the at least one identified terrain event. The operator may subsequently remove the at least one terrain event, for example by removing an obstacle from the terrain <NUM> or by performing maintenance on the terrain <NUM>. In particular, at least one work machine <NUM> may be operated manually or autonomously to travel to the location of the at least one terrain event and adjust the terrain <NUM> to remove, or reduce the negative impact of, the at least one terrain event. For example, the at least one work machine <NUM> may smooth or compact the terrain <NUM> at and/or remove an obstacle or the like from the location of the at least one terrain event.

The operator may be alerted to the location of the terrain event and the operator may adjust the operation of the at least one work machine <NUM> accordingly. In particular, the operator may steer the at least one work machine <NUM> to avoid a terrain event or reduce the speed of the at least one work machine <NUM> to reduce any impact of the terrain event on the at least one work machine <NUM>. The computer system <NUM> may also determine, for example via look up tables or an algorithm, a maximum machine speed limit based upon the properties of the at least one identified terrain event. The maximum machine speed limit may be set based upon the stress and/or strain magnitude and/or rate simulated for the terrain event and the associated event threshold value. The operator may be notified of the maximum machine speed limit or the maximum machine speed limit may be communicated to the machine control system <NUM>, which may subsequently maintain the at least one work machine <NUM> at or below the maximum speed limit when passing over the terrain event.

Any of the aforementioned analyses may be combined in order to improve the productivity and utilisation of the at least one work machine <NUM>. For example, the computer system <NUM> may perform a simulation of the at least one work machine <NUM> travelling at the maximum machine speed along the optimal route <NUM> to determine the productivity of the optimal route <NUM>, such as in terms of fuel efficiency. The overall efficiency of the worksite <NUM> may subsequently be determined.

The system <NUM> may be operated in accordance with a method <NUM> comprising any combination of at least one of the surface profile generating, machine position generating, operating parameter generating, machine model retrieval, simulation and/or analysis steps <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> described above. In any method <NUM>, one or more of the different analyses may be performed in the analysis step <NUM>. Specific embodiments of the method <NUM> are described below.

In a first method the system <NUM> may generate actual surface profile data at the surface profile generating step <NUM>, actual route data at the machine position generating step <NUM> and actual machine operational data at operating parameter generating step <NUM>. As a result, during the simulation step <NUM> the actual operation of at least one work machine <NUM> on the actual worksite <NUM> may be simulated by the computer system <NUM>.

In the structural analysis, stress and/or strain rate analysis and/or structure lifespan analysis the effect on at least one machine structure during the operation of the at least one work machine <NUM> may be monitored via the simulation. The work machine <NUM> may therefore not require a plurality of sensors <NUM> in order to monitor the operating conditions on each of the at least one machine structures. The work machine <NUM> may have a relatively lower production cost and the machine control system <NUM> may have a relatively low complexity due to the absence of a plurality of sensors <NUM>. Processing requirements are therefore reduced. Furthermore, it may be possible to monitor the operating condition of at least one machine structure that cannot be monitored utilising at least one sensor <NUM>. For example, the at least one machine structure may be an internal part of an engine (e.g. a cylinder wall) that cannot be monitored. In addition, provided that a machine model of the at least one work machine <NUM> is available for the machine simulator, the system <NUM> and method <NUM> may be retrofitted or applied to any type of work machine <NUM>.

The structure lifespan analysis and maintenance analysis may enable the lifespans of at least one machine structure of the at least one work machine <NUM> to be tracked and maintenance planned. Servicing schedules and repairs can therefore be based upon when a machine structure actually needs repairing or replacing rather than on a periodic basis. During normal periodic servicing machine structures may be replaced before they have reached the end of their lifespan. However, with the first method the machine structures may be replaced at, or close to, the end of their lifespans. Furthermore, failure of a machine structure may be anticipated based upon the maintenance analysis and the machine structure repaired or replaced. The operator of the at least one work machine <NUM> may also be able to ensure that replacement machine structures are available around the expected expiry of the lifespan of at least one machine structure. As a result, stocks of replacements machine structures may be managed relatively efficiently and downtime reduced, which may occur if replacement machine structures are not available due unexpected failures.

The worksite duty analysis enables the identification of at least one work machine <NUM> being operated on the worksite <NUM> that is not suitable for use on the worksite <NUM> and the identification of at least one more suitable work machine <NUM>. The warranty analysis may enable warranties to be varied and/or matched to at least one work machine <NUM> based upon the actual usage of the at least one work machine <NUM>.

The terrain analysis may enable the route <NUM> and/or terrain <NUM> to be continuously optimised based upon the actual machine data. Where terrain events are identified based upon the actual machine data the route <NUM> may be adapted to avoid the terrain events and/or the terrain <NUM> may be adapted in order to remove the terrain events. Furthermore, the at least one work machine <NUM> may be operated based upon the at least one terrain event, such as by speed limiting, in order to extend the lifetime of, improve the efficiency of and improve the operational safety of the at least one work machine <NUM>.

In a second method the system may generate actual surface profile data at the surface profile generating step <NUM>, actual or simulated route data at the machine position generating step <NUM> and simulated machine operational data at operating parameter generating step <NUM>. As a result, during the simulation step <NUM> the operation of at least one work machine <NUM> on the actual worksite <NUM> may be entirely simulated by the computer system <NUM>. Thus all of the analyses may be similar to the first method, except that the monitored operating condition data may differ slightly if the simulated operating parameters differ from the actual operating parameters of the at least one work machine <NUM> travelling along the route <NUM>.

In the structural analysis, stress and/or strain rate analysis and/or structure lifespan analyses the effect of the actual terrain <NUM> on at least one work machine <NUM> may be simulated. In the worksite duty analysis the worksite <NUM> may be allocated a worksite duty segment, which may be utilised for selection of at least one work machine <NUM> and/or to assess the viability of performing operations at the worksite <NUM>. In the terrain analysis, at least one work machine <NUM> suitable for the worksite <NUM> may be selected and at least one optimised route <NUM> across the worksite <NUM> determined. Therefore, before a work machine <NUM> has been operated on a worksite <NUM> it is possible to perform an analysis of the efficiency of the worksite <NUM> and at least one work machine <NUM> operating on the worksite <NUM>. This enables the selection of a suitable worksite <NUM> by an operator if more than one option for a worksite <NUM> is available them.

In a third method the data relating to at least one machine model, simulation algorithm, surface profile data, simulated route data and simulated machine operational data may be adjusted based upon feedback from actual surface profile data, actual route data and/or actual machine operational data. This feedback may be provided after at least one simulation in accordance with the first and/or second method has been performed.

The actual surface profile data may be initially gathered by at least one surveying device <NUM>. This initial surface profile data may subsequently be updated utilising actual surface profile data gathered by the same or different at least one surveying device <NUM>. For example, a UAV may gather the initial surface profile data of the entire worksite <NUM> and a surveying device <NUM> attached to a work machine <NUM> may gather further surface profile data around the route <NUM>. Alternatively, the at least one surveying device <NUM> may continuously monitor the terrain <NUM> as it changes due to at least one work machine <NUM> moving material around the worksite <NUM>. The further surface profile data may be combined with the initial surface profile data by overwriting the appropriate data. In accordance with this method the actual surface profile data may be kept up-to-date and accurate.

The simulated route data and simulated machine operational data may be utilised in a first simulation in accordance with the second method, in which monitored operating condition data is obtained based upon at least one work machine <NUM> moving along a simulated route in accordance with at least one simulated operating parameter. Subsequently, the at least one work machine <NUM> may be operated on the worksite <NUM> along an actual route and actual route data and actual machine operational data generated. The simulated route data and simulated machine operational data may be updated based upon the actual route data and actual machine operational data. Therefore, in second and further simulations under the first and/or second method the machine simulator may more accurately reflect the operation of the at least one work machine <NUM> on the worksite <NUM>.

In particular, the simulated route data may be made identical to the actual route data and/or the simulated machine operational data may be made identical to the actual machine operational data. All or only part of the simulated route data and simulated machine operational data may be replaced by the actual route data and actual operational data. The simulated route data and simulated machine operational data may be replaced by the actual route data and actual operational data if they differ by more than a route data threshold and/or a machine operational data threshold along all or part of the actual or simulated route. The route data threshold may be in units of distance and may comprise a distance of less than approximately <NUM> meters, less than approximately <NUM> meters, less than approximately <NUM> meters, less than approximately <NUM> meters and/or less than approximately <NUM> meter. The machine operational data threshold may be in the units of the at least one operating parameter (e.g. speed, angle of steering, throttle input and the like) and may comprise a difference of less than approximately <NUM>%, less than approximately <NUM>%, less than approximately <NUM>%, and/or less than approximately <NUM>%.

The actual route <NUM> driven may be the same, or substantially similar to, the simulated route <NUM>. For example, the actual route <NUM> may be within a threshold distance or boundary of the simulated route <NUM>. As a result, the simulated route data may not be updated and in the second and further simulations. Therefore, the second and further simulations may be optimised by virtue of utilising updated simulated machine operational data to improve the accuracy of the machine simulator. Alternatively, if the actual route <NUM> driven is different to the simulated route <NUM>, particularly beyond a threshold distance or boundary of the simulated route <NUM>, the simulated route data may be updated to reflect the actual route data. Therefore, the second and further simulations may be optimised by virtue of utilising updated simulated machine operational data and simulated route data, reflecting the actual use of at least one work machine <NUM>, to improve the accuracy of the machine simulator.

The machine model and/or simulation algorithm may also be updated based upon a comparison of simulated monitored operating condition data and actual monitored operating condition data. The simulated monitored operating condition data may be generated by operating the machine simulator at least once, such as in accordance with the first and/or second method described above or in any combination of the surface profile generating, machine position generating, operating parameter generating, machine model retrieval, simulation and/or analysis steps <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> described above. The at least one work machine <NUM> may subsequently be operated to move along the route <NUM> (or at least a substantially similar route <NUM>) and the at least one sensor <NUM> may monitor at least one actual operating condition that corresponds to the at least one monitored operating condition upon which the simulated monitored operating condition data is based. The at least one sensor <NUM> may therefore generate actual monitored operating condition data indicative of the actual conditions of the at least one operating condition during the movement of the at least one work machine <NUM>. Subsequently, the simulated monitored operating condition data may be compared to the actual monitored operating condition data and the machine model and/or simulation algorithm may be updated. As a result, in subsequent operations of the machine simulator the simulated monitored operating condition data may be more accurate and representative of the actual performance of the at least one work machine <NUM>.

The machine model and/or simulation algorithm may be updated if the actual and simulated monitored operating condition data for at least one machine structure over all or part of the route <NUM> differ by more than a monitored operating condition threshold value. The machine model and/or simulation algorithm may be updated by adjusting at least one structural parameter associated with the generation of the simulated monitored operating condition data for the at least one machine structure. In particular, the at least one structural parameter may be adjusted such that the actual and simulated monitored operating condition data are the same or fall within a predetermined range of one another. Therefore, the machine model and/or simulation algorithm may be updated and corrected as the physical properties of machine structures vary with age.

Claim 1:
A method of monitoring the operation of at least one work machine (<NUM>) comprising:
operating at least one surveying device (<NUM>) to measure a surface profile of a terrain (<NUM>) of a worksite (<NUM>) and generate actual surface profile data indicative of the surface profile;
operating at least one work machine (<NUM>) to move along a route (<NUM>) over the terrain (<NUM>) in accordance with at least one actual operating parameter and generating actual machine operational data indicative of the at least one actual operating parameter, wherein the at least one work machine (<NUM>) comprises at least one machine structure;
operating a navigation system to determine the route (<NUM>) and generate actual route data indicative of the route (<NUM>); and
operating a processing unit (<NUM>) to process the actual route data, actual machine operational data and actual surface profile data to generate simulated monitored operating condition data indicative of at least one monitored operating condition of the at least one work machine (<NUM>) moving along the route (<NUM>) in accordance with the at least one actual operating parameter,
characterised in that
the simulated monitored operating data is indicative of at least one monitored operating condition of the at least one machine structure and the at least one monitored operating condition is different to the at least one operating parameter;
the at least one monitored operating condition comprises a monitored stress and/or strain magnitude and/or rate experienced by at least one machine structure as the at least one work machine (<NUM>) moves along the route (<NUM>); and
at least one terrain event is identified and at least one work machine (<NUM>) is operated based upon the identified terrain event and/or an alert is generated, the at least one terrain event being identified at a location of the terrain (<NUM>) where the monitored stress and/or strain magnitude and/or rate on at least one machine structure exceeds an event threshold value.