US20130304331A1 - Display-Based Control for Motor Grader - Google Patents

Display-Based Control for Motor Grader Download PDF

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Publication number
US20130304331A1
US20130304331A1 US13/468,630 US201213468630A US2013304331A1 US 20130304331 A1 US20130304331 A1 US 20130304331A1 US 201213468630 A US201213468630 A US 201213468630A US 2013304331 A1 US2013304331 A1 US 2013304331A1
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United States
Prior art keywords
blade
curb
motor grader
gap
accordance
Prior art date
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Abandoned
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US13/468,630
Inventor
Michael Braunstein
Yongliang Zhu
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Caterpillar Inc
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Caterpillar Inc
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Publication date
Application filed by Caterpillar Inc filed Critical Caterpillar Inc
Priority to US13/468,630 priority Critical patent/US20130304331A1/en
Assigned to CATERPILLAR, INC. reassignment CATERPILLAR, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ZHU, YONGLIANG, BRAUNSTEIN, MICHAEL
Publication of US20130304331A1 publication Critical patent/US20130304331A1/en
Abandoned legal-status Critical Current

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Classifications

    • EFIXED CONSTRUCTIONS
    • E02HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02FDREDGING; SOIL-SHIFTING
    • E02F3/00Dredgers; Soil-shifting machines
    • E02F3/04Dredgers; Soil-shifting machines mechanically-driven
    • E02F3/76Graders, bulldozers, or the like with scraper plates or ploughshare-like elements; Levelling scarifying devices
    • E02F3/80Component parts
    • E02F3/84Drives or control devices therefor, e.g. hydraulic drive systems
    • E02F3/844Drives or control devices therefor, e.g. hydraulic drive systems for positioning the blade, e.g. hydraulically
    • EFIXED CONSTRUCTIONS
    • E02HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02FDREDGING; SOIL-SHIFTING
    • E02F3/00Dredgers; Soil-shifting machines
    • E02F3/04Dredgers; Soil-shifting machines mechanically-driven
    • E02F3/76Graders, bulldozers, or the like with scraper plates or ploughshare-like elements; Levelling scarifying devices
    • E02F3/7636Graders with the scraper blade mounted under the tractor chassis
    • E02F3/764Graders with the scraper blade mounted under the tractor chassis with the scraper blade being pivotable about a vertical axis
    • EFIXED CONSTRUCTIONS
    • E02HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02FDREDGING; SOIL-SHIFTING
    • E02F3/00Dredgers; Soil-shifting machines
    • E02F3/04Dredgers; Soil-shifting machines mechanically-driven
    • E02F3/76Graders, bulldozers, or the like with scraper plates or ploughshare-like elements; Levelling scarifying devices
    • E02F3/7636Graders with the scraper blade mounted under the tractor chassis
    • E02F3/7645Graders with the scraper blade mounted under the tractor chassis with the scraper blade being pivotable about a horizontal axis disposed parallel to the blade
    • EFIXED CONSTRUCTIONS
    • E02HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02FDREDGING; SOIL-SHIFTING
    • E02F3/00Dredgers; Soil-shifting machines
    • E02F3/04Dredgers; Soil-shifting machines mechanically-driven
    • E02F3/76Graders, bulldozers, or the like with scraper plates or ploughshare-like elements; Levelling scarifying devices
    • E02F3/7636Graders with the scraper blade mounted under the tractor chassis
    • E02F3/765Graders with the scraper blade mounted under the tractor chassis with the scraper blade being pivotable about a horizontal axis disposed perpendicular to the blade
    • EFIXED CONSTRUCTIONS
    • E02HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02FDREDGING; SOIL-SHIFTING
    • E02F3/00Dredgers; Soil-shifting machines
    • E02F3/04Dredgers; Soil-shifting machines mechanically-driven
    • E02F3/76Graders, bulldozers, or the like with scraper plates or ploughshare-like elements; Levelling scarifying devices
    • E02F3/7636Graders with the scraper blade mounted under the tractor chassis
    • E02F3/7659Graders with the scraper blade mounted under the tractor chassis with the vertical centre-line of the scraper blade disposed laterally relative to the central axis of the chassis
    • EFIXED CONSTRUCTIONS
    • E02HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02FDREDGING; SOIL-SHIFTING
    • E02F3/00Dredgers; Soil-shifting machines
    • E02F3/04Dredgers; Soil-shifting machines mechanically-driven
    • E02F3/76Graders, bulldozers, or the like with scraper plates or ploughshare-like elements; Levelling scarifying devices
    • E02F3/80Component parts
    • E02F3/84Drives or control devices therefor, e.g. hydraulic drive systems
    • E02F3/841Devices for controlling and guiding the whole machine, e.g. by feeler elements and reference lines placed exteriorly of the machine
    • E02F3/842Devices for controlling and guiding the whole machine, e.g. by feeler elements and reference lines placed exteriorly of the machine using electromagnetic, optical or photoelectric beams, e.g. laser beams
    • EFIXED CONSTRUCTIONS
    • E02HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02FDREDGING; SOIL-SHIFTING
    • E02F3/00Dredgers; Soil-shifting machines
    • E02F3/04Dredgers; Soil-shifting machines mechanically-driven
    • E02F3/76Graders, bulldozers, or the like with scraper plates or ploughshare-like elements; Levelling scarifying devices
    • E02F3/80Component parts
    • E02F3/84Drives or control devices therefor, e.g. hydraulic drive systems
    • E02F3/844Drives or control devices therefor, e.g. hydraulic drive systems for positioning the blade, e.g. hydraulically
    • E02F3/847Drives or control devices therefor, e.g. hydraulic drive systems for positioning the blade, e.g. hydraulically using electromagnetic, optical or acoustic beams to determine the blade position, e.g. laser beams
    • EFIXED CONSTRUCTIONS
    • E02HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02FDREDGING; SOIL-SHIFTING
    • E02F9/00Component parts of dredgers or soil-shifting machines, not restricted to one of the kinds covered by groups E02F3/00 - E02F7/00
    • E02F9/26Indicating devices
    • E02F9/261Surveying the work-site to be treated
    • E02F9/262Surveying the work-site to be treated with follow-up actions to control the work tool, e.g. controller

Definitions

  • the present disclosure relates to motor grader operation and, more particularly, relates to motor grader blade and steering control for operations near roadway markers such as curbs.
  • Motor graders are earth-moving machines that are employed in a variety of tasks, including as shaping tools to create banks, ditches, and berms, as surface preparation tools for scarification and other surface treatments, and as finishing tools to refine construction site and roadway surfaces to final shape and contour.
  • motor graders typically include a front frame and a rear frame that are joined at an articulation joint.
  • the rear frame includes compartments for housing the power source and cooling components, the power source being operatively coupled to the rear wheels for primary propulsion of the machine.
  • the rear wheels are typically arranged in tandem sets on opposing sides of the rear frame.
  • the front frame typically includes a pair of front wheels, and supports an operator station and a blade assembly.
  • the motor grader blade can generally be rotated, tilted, raised, lowered, and/or shifted side to side to any of a large number of positions with fine resolution of motion.
  • the blade is affixed to the motor grader, the relative blade position is highly variable.
  • Overall steering of the machine is generally a function of both front wheel steering (typically referred to as “steering”) and articulation of the front frame relative to the rear frame (typically referred to as “articulation”). This allows the machine to navigate relatively tight arcs and circles such as may occur at curves or turns in a roadway. Given the ability to control the blade position, frame articulation, and wheel steering, the operation of a motor grader presents users with a complex task.
  • the operator interface to control the machine generally includes various hand-operated controls to steer the front wheels, position the blade, control frame articulation, and control auxiliary devices such as rippers and plows, while also including various displays for monitoring machine conditions and/or functions.
  • the term “marker” refers to a structure to be followed such as a curb. While a marker need not be specifically marked with a visible paint or other marking substance, the term “marker” does not exclude such visually marked structures.
  • U.S. Appl. No. 2010/0010703 to Coats et al. discloses a method for machine guidance that is directed to maintaining a machine position relative to a marker. While the system of Coats et al. does assist operators by automating certain machine positioning tasks, it does not address blade positioning for sensitive operations such as cul-de-sac grading and contouring.
  • the present disclosure is directed to a machine control system and method to improve motor grader operations in order to address one or more of the problems or shortcomings set forth above.
  • the solution of any particular problem is not a limitation on the scope of this disclosure and the attached claims except to the extent expressly noted.
  • this background section discusses problems and solutions noted by the inventors; the inclusion of any problem or solution in this section is not an indication that the problem or solution represents known prior art except as otherwise expressly noted. With respect to prior art that is expressly noted as such, the summary thereof is not intended to alter or supplement the prior art document itself; any discrepancy or difference should be resolved by reference to the prior art.
  • a method of controlling a motor grader includes displaying a blade image on a display screen to an operator of the motor grader, the blade image having a representation of at least a portion of the blade and at least a portion of a curb adjacent the motor grader.
  • Input is received from the operator to move the blade such that a gap between the portion of the blade and the portion of the curb conforms to a target distance.
  • the gap between the portion of the blade and the portion of the curb is monitored as the motor grader moves along the curb and the location of the blade relative to the curb is adjusted such that the gap remains at the target distance.
  • the blade image is updated as the motor grader moves along the curb.
  • a controller for providing display-based control of a motor grader having a blade for grading an underlying surface.
  • the controller includes computer-executable instructions on a computer-readable medium for displaying a blade image on a display screen to an operator of the motor grader, the blade image having a representation of at least a portion of the blade and at least a portion of a curb adjacent the motor grader.
  • Instructions are included for receiving an input from the operator to move the blade such that a gap between the portion of the blade and the portion of the curb conforms to a target distance and for monitoring the gap as the motor grader moves along the curb and adjusting the location of the blade relative to the curb such that the gap continues to conform to the target distance.
  • the instructions also include instructions for updating the blade image as the motor grader moves along the curb.
  • a system for controlling a motor grader during grading near a curb, the motor grader having a blade for grading an underlying surface.
  • the system includes a display for displaying to an operator of the motor grader an image showing a gap between the blade and the curb and for receiving user input to alter the gap to a target distance.
  • a controller is configured to adjust a position of the blade during grading of the underlying surface to maintain the gap between the blade and the curb at the target distance.
  • FIG. 1 is a pictorial representation of a side view of an exemplary motor grader
  • FIG. 2 is a pictorial representation of a top view of an exemplary motor grader
  • FIG. 3 is a diagrammatic illustration of a top view of an exemplary motor grader illustrating steering and articulation angles
  • FIG. 4 is a control schematic showing controller inputs and outputs used in implementing various embodiments of the disclosed systems and methods
  • FIG. 5 is a flow chart illustrating an overview process for operation of certain aspects of a motor grader machine based on a mode selection by the operator;
  • FIG. 6 is a flow chart illustrating an automatic blade control process in accordance with one implementation of the disclosure.
  • FIG. 7 is a flow chart illustrating an automatic blade and articulation control process in accordance with one implementation of the disclosure.
  • FIG. 8 is a flow chart illustrating an automatic blade, steering, and articulation control process in accordance with one implementation of the disclosure
  • FIG. 9 is a schematic example of a display or “blade image” for allowing user selection of certain parameters.
  • FIG. 10 is a record image display of a worksite showing areas that have and have not been graded according to an aspect of the disclosure.
  • the present disclosure provides a system and method for motor grader steering and blade control for operations relative to roadway markers such as, but not limited to, curbs and the like.
  • FIG. 1 and FIG. 2 there is shown an exemplary motor grader in accordance with one embodiment of the present disclosure.
  • the illustrated motor grader 10 includes a front frame 12 , rear frame 14 , and a work implement 16 .
  • the work implement 16 is typically a blade assembly 18 , also sometimes referred to as a drawbar-circle-moldboard assembly (DCM).
  • the blade assembly 18 may include a separate blade portion and a moldboard portion, and such arrangements will be referred to herein collectively as the blade, moldboard, or DCM.
  • the rear frame 14 includes a power source, not shown, contained within a rear compartment 20 .
  • the power source is typically operatively coupled through a transmission, not shown, to rear traction devices or wheels 22 for primary machine propulsion.
  • the rear wheels 22 are operatively supported on tandems 24 which are pivotally connected to the machine between the rear wheels 22 on each side of the motor grader 10 .
  • the power source may be, for example, a diesel engine, a gasoline engine, a natural gas engine, or any other engine known in the art.
  • the power source may additionally or alternatively comprise a battery, fuel cell or other electrical power storage device known in the art.
  • the transmission may be a mechanical transmission, hydraulic transmission, or any other transmission type known in the art and may be operable to produce multiple output speed ratios (or a continuously variable speed ratio) between the power source and driven traction devices.
  • the front frame 12 supports an operator station 26 containing various operator controls, along with a variety of displays or indicators used to convey information to the operator, used for primary operation of the motor grader 10 .
  • the front frame 12 also includes a beam 28 that supports the blade assembly 18 .
  • the blade assembly 18 includes a drawbar 32 pivotally mounted to a first end 34 of the beam 28 via a ball joint (not shown).
  • the position of the drawbar 32 is controlled by three hydraulic cylinders: a right lift cylinder 36 and left lift cylinder 38 that control vertical movement, and a center shift cylinder 40 that controls horizontal movement.
  • the blade 30 may be shifted sideways relative to the front frame 12 via shifting of the blade 30 itself or via shifting of the drawbar 32 .
  • the right and left lift cylinders 36 , 38 are connected to a coupling 70 that includes lift arms 72 pivotally connected to the beam 28 for rotation about axis C.
  • a bottom portion of the coupling 70 has an adjustable length horizontal member 74 that is connected to the center shift cylinder 40 .
  • the drawbar 32 includes a large, flat plate, commonly referred to as a yoke plate 42 . Beneath the yoke plate 42 is a circular gear arrangement and mount, commonly referred to as the circle 44 .
  • the circle 44 is rotated by, for example, a hydraulic motor referred to as the circle drive 46 . In other embodiments, an electric motor is used to facilitate rotation of the circle 44 .
  • the blade circle angle refers to the angle of the blade 16 relative to a longitudinal axis 48 of the front frame 12 .
  • the blade 30 is aligned across the machine 10 at a right angle to the longitudinal axis 48 of the front frame 12 and beam 28 , as shown in FIG. 2 .
  • a pivot assembly 50 between the blade 30 and the circle 44 allows for tilting of the blade 30 relative to the circle 44 .
  • a blade tip cylinder 52 is used to tilt the blade 30 forward or rearward.
  • the blade tip cylinder 52 is used to tip or tilt a top edge 54 relative to the bottom cutting edge 56 of the blade 30 , and the occurrence or extent of this tilting is commonly referred to as blade “tip.”
  • the blade 30 can be shifted to the left or right by the blade side shift cylinder 53 along directions D.
  • steerable traction devices (right wheel 58 and left wheel 60 in the illustrated example) are associated with the first end 34 of the beam 28 .
  • the right wheel 58 and left wheel 60 may be rotatable and tiltable for use during steering and leveling of a work surface 86 .
  • the right wheel 58 and left wheel 60 are connected via a steering apparatus 88 that may include a tie rod 90 for pivoting the wheels in unison about pivot points 80 as well as one or more wheel tilt actuators 91 to provide front wheel tilt.
  • the motor grader 10 includes an articulation joint 62 that pivotally connects front frame 12 and rear frame 14 at an articulation axis B. Both a right articulation cylinder 64 and a left articulation cylinder 66 are connected between the front frame 12 and the rear frame 14 on opposing sides of the machine 10 . The right and left articulation cylinders 64 , 66 are used to pivot the front frame 12 relative to the rear frame 14 , separated at articulation axis B. In the illustrative example of FIG. 2 , the motor grader 10 is positioned in the neutral or zero articulation angle position wherein the longitudinal axis 48 of the front frame 12 is aligned with a longitudinal axis 68 of the rear frame 14 .
  • FIG. 3 provides a top view of the motor grader 10 with the front frame 12 rotated at an articulation angle ⁇ defined by the intersection of longitudinal axis 48 of front frame 12 and longitudinal axis 68 of the rear frame 14 , the intersection corresponding with the position of articulation joint 62 .
  • This illustration follows the convention that a positive a value is indicative of a left articulation from the perspective of an operator facing forward, while a negative a value would be indicative of a right articulation.
  • a front wheel steering angle ⁇ is defined between a longitudinal axis 76 parallel to the longitudinal axis 48 of front frame 12 , and a longitudinal axis 78 of the front wheels 58 , 60 , the angle ⁇ having an origin at the pivot point 80 of the front wheels 58 , 60 .
  • This is demonstrated in connection with left front wheel 60 , but also applies to the right front wheel 58 . It will be appreciated that in order for the turn centers of the front wheels 58 , 60 to coincide as shown, one may have a slightly different steering angle from the other, with the outside wheel generally having a longer radius.
  • the motor grader 10 has many degrees of freedom, both in steering and in blade position, that provide the ability to perform precise work; however, these various degrees of freedom must be carefully controlled to provide the best work product and operator experience. As noted above, cul-de-sac operations can be especially challenging, given the need to precisely steer the motor grader 10 while simultaneously positioning the blade assembly 18 with sufficient accuracy, particularly in the shift dimension, to avoid curb damage or incomplete grading.
  • a number of special machine modes are provided including an automatic blade mode wherein the blade assembly 18 is automatically positioned relative to a road marker such as a curb or roadway edge while the operator controls the positioning of the machine 10 via steering and articulation.
  • machine articulation is automated as well, such that the articulation and blade shift are controlled cooperatively to maintain a desired spacing between the edge of the blade assembly 18 and the marker.
  • a fully automated mode provides automatic control of blade side shift, frame articulation, and wheel steering.
  • machine speed may be controlled or limited.
  • an embodiment of the disclosure employs a controller 94 for receiving and evaluating machine commands such as mode selections.
  • the controller 94 is also configured to receive and evaluate machine data, such as steering angle, blade angle, blade shift, blade tilt, machine speed, etc.
  • the controller 94 may receive and evaluate sensor data, such as the location of the roadway marker adjacent the machine, the curvature of, or downrange points on, the marker, and so on.
  • the controller 94 also provides data and control outputs as needed to execute the methodology described herein depending upon the mode selected, e.g., setting the shift of the blade assembly 18 , setting the steering and tilt angle of one or more machine wheels, setting the angle of articulation, etc.
  • the controller 94 is implemented, in an embodiment, as a computing device incorporating one or more microcontrollers and/or microprocessors (collectively referred to herein as a “processor” or “digital processor”).
  • the controller 94 operates by reading or loading computer-executable instructions, or code, from a nontransitory computer-readable medium such as a nonvolatile memory, a magnetic or optical disc memory, a flash drive, and so on. To the extent that the read instructions are associated with and accessible to the controller 94 , the controller 94 may be said to include such instructions.
  • the controller 94 may execute the instructions in a time-shared manner, a multi-thread manner, or any other suitable execution technique. It will be appreciated that data used by the controller 94 in the execution of the computer-executable instructions may be stored and read out as well, or may be created in real time.
  • the controller 94 has one or more interfaces to receive data and/or commands, and one or more outputs to output data and/or commands such as those discussed above.
  • the controller 94 may be an isolated controller or is alternatively implemented within another controller that also serves other machine functions.
  • the controller 94 receives a steering angle sensor input signal 96 from one or more steering angle sensors 98 .
  • This steering angle sensor input signal 96 provides a signal indicative of the steering angle.
  • a signal is indicative of a specified quantity or value when it directly or indirectly conveys or can be used to calculate, directly or indirectly, that quantity or value.
  • each signal may be communicated over a dedicated physical line or channel, or may be multiplexed over a multi-signal channel, as may be the case in the event that the machine 10 utilized a managed machine area network. In either case, one or more input signals may be communicated at least partially by wireless transmission.
  • the controller 94 further receives a steering input signal 100 from one or more operator steering controls 102 indicative of an operator steering command.
  • the steering input signal is received from steering angle sensors 98 .
  • the operator steering controls 102 may include a joy stick as shown in FIGS. 1-2 , or any other type of operator input device, such as a dial, keyboard, pedal or other devices known in the art.
  • a steering angle sensor is configured to sense the rotation or position of the operator steering controls 102 and to provide a steering input signal 100 indicative of a steering angle ⁇ .
  • the controller 94 further receives an articulation input signal 104 from one or more articulation sensors 106 , with the articulation input signal 104 being indicative of the articulation angle ⁇ at the axis B between the rear frame 14 and front frame 12 .
  • the one or more articulation sensors 106 include a pivot sensor disposed at articulation joint 62 to sense rotation about articulation axis B. Additionally or alternatively, the one or more articulation sensors 106 may include one or more sensors configured to monitor the extension of right and/or left articulation cylinders 64 , 66 .
  • steering angle sensors 98 steering wheel sensor (at operator steering controls 102 ), articulation sensors 106 , as well as other sensors for rotational movement may be, for example, potentiometers, extension sensors, proximity sensors, angle sensors, rotary encoders, and the like.
  • one or more blade position sensors 110 provide a blade position input signal 108 to the controller 94 , the blade position input signal 108 being indicative of the actual position of the blade 30 .
  • Such sensors may be configured to sense blade position directly or may be configured to sense blade position indirectly (for example from pin angle sensors, etc.) based on the positions of the related hydraulic actuators.
  • the blade position in at least the shift direction is sensed via a non-contact sensor (“object sensor”), e.g., digital camera, LADAR, LIDAR, etc.
  • object sensor e.g., digital camera, LADAR, LIDAR, etc.
  • the blade position input signal 108 may also indicate a position of the blade 30 in other dimensions as well, such as tilt, tip, and rotation.
  • a blade position command input signal 124 originating from an operator blade positioning input device 126 provides the controller 94 with information regarding an operator's inputs to position the blade 30 .
  • the operator blade positioning input device 126 may be any suitable operator control for setting blade position, including but not limited to one or more joysticks, levers, and the like.
  • One or more transmission sensors 114 may be used, associated with the transmission, to provide a gear input signal 112 indicative of a current gear or output ratio associated with the machine transmission.
  • the gear input signal 112 may be provided by signals associated with operator controls for the transmission (not shown).
  • one or more marker sensors 118 (“object sensors”) provide a marker position input signal 116 to the controller 94 .
  • the one or more marker sensors 118 include only a single sensor, which is selectively directed to one side of the machine 10 or the other depending upon which side of the machine 10 the roadway marker is known or detected to be located.
  • the one or more marker sensors 118 may include multiple stationary sensors or a more limited number of scanning sensors, or a combination of stationary and scanning sensors.
  • a scanning sensor in this context is one that can be dynamically directed to a different field of view, e.g., it may be selectively directed forward or sideways, downward or sideways, left side or right side, etc.
  • virtual sensor arrays may be implemented from a single sensor via synthetic array heterodyne detection schemes and the like to enhance the capabilities of individual sensors.
  • the one or more marker sensors 118 may include one or more LIDAR (light detection and ranging) sensors, one or more LADAR (laser detection and ranging) sensors, one or more digital cameras, and/or other types of sensors.
  • LIDAR sensing involves the emission and detection of UV, visible or near infrared radiation to determine a distance between the sensor and a target object, e.g., the roadway marker.
  • LADAR involves the use of laser radiation to detect the distance to the target object.
  • LADAR may also operate in areas of the electromagnetic spectrum not used by LIDAR.
  • LADAR can generally provide better long range accuracy than LIDAR
  • the systems and processes of this disclosure entail short range detection.
  • cameras typically provide accurate ranging information only at short ranges relative to both LADAR and LIDAR, but cameras do provide suitable ranging capabilities within the close ranges contemplated herein.
  • the selection of sensor type, number, and position may be resolved by issues of cost and availability as well as any considerations of multi-purposing of sensors rather than questions of efficacy.
  • a single sensor may be used for both object detection and personnel detection, or for other additional purposes.
  • all or a subset of the one or more marker sensors 118 in conjunction with the processor may be configured to preferentially detect a specific marking, material, or quality associated with the roadway marker.
  • a curb can be characterized by a longitudinal block of a certain color or color range bounded by linear boundaries to other colors such as the color of soil, grass, etc.
  • a non-naturally occurring color may be applied to the curb to provide a signal for the one or more marker sensors 118 to preferentially detect.
  • a continuous stripe of bright white or neon orange paint may be applied to the curb to aid in detection and/or ranging.
  • the detected non-naturally occurring color would identify a target, e.g., the curb, upon which ranging occurs.
  • a propulsion input signal 120 is provided to the controller 94 from one or more operator-controlled propulsion interface devices 122 , e.g., acceleration pedals or levers, transmission mode selectors, etc. Such interface devices 122 may be located in the operator station 26 .
  • An engine speed input signal 121 is also provided to the controller 94 in an embodiment, with the associated engine speed data originating from an RPM sensor 123 or the like.
  • a machine position sensor cluster 130 is configured to provide the controller 94 with a machine position input signal 128 .
  • the machine position sensor cluster 130 may include without limitation one or more accelerometers, inclinometers, inertial measurement units, and other orientation sensors, as well as a GPS or other positioning system.
  • the machine position input signal 128 provides the controller 94 with information regarding both the position and orientation of the machine 10 .
  • a mode selection option for the operator is enabled in an embodiment of the disclosure.
  • the mode selection option may be presented via a mode selector switch 134 which provides a mode selection signal 132 to the controller 94 .
  • the mode selector switch 134 may be employed to select amongst various modes of operation including, for example, a blade automation mode, a blade and articulation automation mode, a full auto mode and a normal or manual mode.
  • each output signal may be provided over a dedicated physical line or channel, or all outputs may be multiplexed over a lesser number of non-dedicated lines or channels.
  • one or more outputs may be communicated at least partially by wireless transmission.
  • the controller 94 provides a steering output 136 to set the steering angle of the front wheels of the machine 10 .
  • the steering output 136 may be provided to a system controller that implements the steering command.
  • the steering output 136 may be provided to and processed by the same logic and hardware that process the steering commands from the operator steering controls, which further actuates hydraulic cylinders (not shown) of the steering apparatus 88 so as to implement the steering command.
  • the steering output 136 may be overridden by the operator in an embodiment.
  • the controller 94 For controlling the articulation of the machine 10 when in a mode requiring such control, the controller 94 provides an articulation output 138 .
  • the articulation output 138 may be provided to another controller or subsystem responsible for implementing articulation commands.
  • the articulation output 138 may be implemented via independent hardware and processing. In either case, the indicated articulation command is used to control machine frame articulation, e.g., via the articulation actuators 64 , 66 .
  • the controller 94 In order to control the position of the blade 30 to maintain distance between the blade and the roadway marker during operations (“target distance”), the controller 94 provides a blade shift output 140 .
  • the blade shift output 140 may be provided to a control solenoid associated with a hydraulic control valve for the blade side shift cylinder 53 and/or the center shift cylinder 40 via the same hardware as the operator-input shift commands or via an independent channel or circuitry.
  • the controller 94 provides a machine speed output 142 .
  • the machine speed output 142 may contain, or may be used to generate, commands for controlling machine engine speed, drive speed, and/or transmission mode or range. For example, for rough ground conditions, it may desirable to maintain a constant torque at the traction elements, whereas in an environment having significant gradient variation, it may be desired to maintain a constant machine speed.
  • controller 94 may be linked to the controller 94 in a traditional manner, and such are not itemized and illustrated herein.
  • the controller 94 outputs a display signal to a display screen in keeping with the display features and aspects discussed herein. Although such images are novel, the way in which the controller 94 causes a given image to be displayed will be known to those of skill in the art.
  • FIGS. 5-8 Exemplary processes utilized by the controller 94 in an embodiment to control blade distance to the roadway marker in various modes are shown in FIGS. 5-8 . While the disclosure will exemplify these processes as being executed by the controller 94 , it will be appreciated that the processes may be distributed as needed or desired in a given implementation. Moreover, it will be appreciated that the order of steps within each process is illustrative, and the steps need not occur in the given order unless otherwise apparent from the disclosure. Moreover, while the disclosure explains operations in various selectable modes, it is also contemplated, without departing from the scope of these teachings, for a machine in a particular implementation to support only a subset of the described modes, or indeed, to support only a single mode.
  • an overview process 150 is shown for operation of certain aspects of the machine based on a mode selection by the operator, e.g., by way of the mode selector switch 134 .
  • the process 150 is used in order to identify further processes for execution based on mode selection.
  • the controller 94 receives a mode selection signal from the mode selector switch 134 .
  • the mode selection signal identifies a desired mode of operation, selected from among available modes, e.g., manual, automatic blade control, automatic blade and articulation control, and fully automatic control.
  • the process 150 determines subsequently at stage 154 which of the available modes has been selected, and terminates if manual operation has been selected, continues to jump point A (see FIG. 6 ) if automatic blade control has been selected, continues to jump point B (see FIG. 7 ) if automatic blade and articulation control has been selected, and continues to jump point C (see FIG. 8 ) if fully automatic control has been selected.
  • the modes other than the manual mode may be locked out, i.e., not selectable, if the machine speed is higher than a predetermined acceptable speed.
  • an automatic blade control process 160 is shown.
  • the automatic blade control process 160 is entered at jump point A, and begins with optional stage 162 , wherein the controller 94 receives a marker sensor position signal, e.g., an indication of whether a marker sensor such as a camera, LIDAR sensor, or other marker sensor is facing to the left of the machine 10 or to the right.
  • the controller 94 may determine an appropriate direction for the marker sensor and position the marker sensor automatically.
  • the controller 94 can scan the sensor on a first side of the machine 10 , e.g., the right side, for a curb or other marker, and if one is found, maintain the sensor in that orientation. If a curb or other marker is not found in a scan of the right side, the controller 94 may then scan the sensor on the opposite side of the machine 10 .
  • the marker sensor position signal may indicate which marker sensor is to be active, e.g., on which side of the machine 10 the marker has been detected. In an alternative embodiment, the operator selects which sensor is to be active or which direction a single sensor is to face.
  • the controller 94 may prompt the operator via a visual display to set certain aspects of the blade positioning to the desired setting, e.g., to set a desired blade tip, tilt, and circle shift. Having determined the marker sensor position, the process 160 flows to stage 164 , wherein the controller 94 determines the distance from the blade 30 to the detected marker, e.g., the curb or other marker. While a given sensor such as a camera, LIDAR sensor, LADAR sensor, etc. will typically only determine the distance between the sensor itself and the marker, the controller 94 may then process that distance information given the known sensor position relative to the machine and the known blade position relative to the machine to determine the distance from the blade edge to the marker.
  • the controller 94 may then process that distance information given the known sensor position relative to the machine and the known blade position relative to the machine to determine the distance from the blade edge to the marker.
  • the detected marker structure may be displayed to the user, who then selects which feature to follow.
  • a square curb may have four or more linear features including those in the base, and the user can select a feature of the displayed structure against which distance is to be measured.
  • the operator is also prompted to set an acceptable blade gap.
  • the operator may be shown a camera view of the blade and marker on a display and may set a gap on the screen visually or numerically, or may manually shift the blade while watching the display until the desired gap is achieved.
  • the operator is prompted to confirm the closest feature.
  • the operator is prompted to input a distance value.
  • FIG. 9 A schematic example of a display for allowing user selection of parameters is shown in FIG. 9 .
  • This image is referred to herein as a blade image, and in general shows at least a portion of a curb adjacent the motor grader 10 and at least a portion of the blade 30 so that the operator may visualize the gap and in some embodiments adjust the gap via the display in the case of a touch screen display.
  • the blade image may be photographic, e.g., showing data gathered by a camera aimed at the area including a portion of the blade and a portion of the curb, or may be computer generated as in the illustrated example.
  • the illustrated selection display 206 shows the detected linear features of a curb 208 in cross-section as curb point A ( 210 ), curb point B ( 212 ) and curb point C ( 214 ).
  • a marking such as a bright paint may be applied to the curb, either along the entire length to be tracked or periodically, to enhance the ability of the sensor to detect and distinguish the curb or certain features of the curb.
  • Each curb point 210 , 212 , 214 is associated with a tracking curve, i.e., tracking curve A ( 216 ), tracking curve B ( 218 ), and tracking curve C ( 220 ).
  • the blade 30 is represented in the display 206 by blade outline 222 .
  • the display 206 includes one or more parameter fields allowing the operator to enter desired parameters.
  • the display 206 includes a blade gap field 224 in which the operator may enter a numerical blade gap, as well as a finish selection field 226 for selection when finished setting the gap.
  • the user may also set the blade gap manually while watching the display 206 or, in a further embodiment, may set the gap by manipulating the display itself via a cursor selection or touch screen operation.
  • the operator In selecting a curb point to measure against, the operator also selects the corresponding tracking curve in an embodiment. Because the mechanisms associated with the blade 30 cannot react instantaneously, the curve allows the controller 94 to predict and accommodate upcoming curves and discontinuities.
  • the tracking curves 216 , 218 , 220 need not precisely track the selected curb point. Rather, a tracking curve may be interpolated across minor gaps or discontinuities of a particular curb point, such as a gap for a gutter grate, manhole cover opening, etc.
  • the interpolated tracking curve during a discontinuity is comprised of a curve segment that connects the last non-interpolated point before the gap and the first non-interpolated point after the gap.
  • the curve segment has a curvature in this embodiment that is substantially the average of the curve values immediately before and immediately after the gap. Local curvatures may be identified by a radius, a polynomial expression, or otherwise.
  • the tracking curve may exhibit a termination, i.e., where there is no far side point on the curve visible, instead of a gap where a far side point can be detected.
  • the tracking process may fix the blade position at its current position until the curve is again detected, terminate automatic blade control, or shift the blade 30 sideways away from the curb side.
  • Other responses may be appropriate depending upon the implementation environment. For example, if the tracked curb or other marker is known to be circular or to follow some other predefined path, the tracking process may continue to track the virtual known curve even in the absence of a detectable actual curb or other marker.
  • the controller 94 moves the blade 30 at stage 166 to the extent needed so that the distance from the blade edge to the marker matches a target blade gap distance, which may be as little as about 30 mm or less, depending upon machine resolution of motion, up to much larger gap distances, as may be required when working near curbs having extended base portions.
  • a target blade gap distance is a preset value, and in an alternative embodiment the operator may select a target distance to be maintained as noted above.
  • the controller 94 maintains the gap between the blade 30 and the selected curve by adjusting blade side shift via the blade side shift cylinder 53 and/or the center shift cylinder 40 .
  • blade side shift is primarily used to adjust the gap, with center shift then being used as needed.
  • the distance from the blade 30 to the selected curve may be accomplished via a combination of both side shift and circle angle adjustment in an embodiment.
  • the circle angle is pre-determined or pre-set. Alternatively, the operator may elect to manually control this function during the course of operations.
  • the circle angle is automatically controlled to maintain a predetermined angle, or to stay within a predetermined angle range, based a tangent of the marker relative to the circle angle.
  • the blade shift executed in stage 167 is limited to a predetermined percentage of the range of blade shift available to allow some reserve capacity to shift further if need be.
  • the shift may be limited at stage 167 to 75% of the total available range.
  • a warning indicator is provided, in an embodiment, when the side shift reaches the preset limit value.
  • the controller determines at stage 169 whether the operator has steered the machine 10 out of range of the marker. If the operator has steered the machine 10 out of range of the marker, then the process 160 lifts the blade at stage 170 and reverts the machine to manual control. If instead it is determined at stage 169 that the operator has not steered the machine 10 out of range of the marker, the process 160 loops back to stage 162 to reevaluate and further refine blade position as the machine 10 moves forward.
  • a warning may be given before reverting to manual control. For example, a visual or audible warning may indicate that the blade gap distance is in danger of going out of range, that the machine is travelling too fast, etc.
  • one or more other conditions may also cause the machine 10 to revert to manual control.
  • the process 160 is terminated and the machine 10 reverted to manual operation whenever the operator manipulates the blade side shift manually, e.g., via operator controls in the operator station 26 .
  • the controller 94 operates according to the automatic blade and articulation control process 172 shown in FIG. 7 , which is initially similar to the automatic blade control process 160 .
  • the process 172 is entered at jump point B, and begins with optional stage 174 , wherein the controller 94 receives a marker sensor position signal or determines an appropriate direction for the marker sensor and positions the marker sensor automatically as discussed above.
  • the controller 94 may prompt the operator via a visual display to set certain aspects of the blade positioning to the desired setting, e.g., to set a desired blade tip, tilt, and circle shift, as discussed with respect to process 160 .
  • the controller 94 determines the distance from the blade 30 to the detected marker at stage 176 and moves the blade 30 at stage 178 to the extent needed so that the distance from the blade edge to the marker matches the preset blade gap distance if the user has not manually set the gap.
  • the detected marker structure may be displayed to the user, who then selects which feature to follow and sets an appropriate gap.
  • the controller 94 maintains the gap initially set between the blade 30 and the selected curve by adjusting blade side shift via the blade side shift cylinder 53 and/or the center shift cylinder 40 at stage 179 .
  • the blade shift is limited to less than the actual available range of blade side shift, e.g., 75% of the total available range.
  • a warning indicator may be provided when the side shift reaches the preset limit value.
  • the controller 94 In addition to checking and setting blade position, the controller 94 also controls the machine articulation in the instant embodiment.
  • the control of articulation serves three purposes, namely ensuring compliance with certain rules of motion, providing additional side shift capability, and allowing the rear wheels to track the front wheels to the extent such is compatible with the other goals of articulation.
  • the controller senses the steering angle ⁇ , e.g., via steering input signal 100 at stage 180 .
  • the controller 94 adjusts the frame articulation angle ⁇ (as sensed via the articulation input signal 104 and controlled via the articulation output 138 to right and left articulation cylinders 64 , 66 ) based on (1) certain rules of travel, e.g., disallowing impact of rear wheels on curb, (2) the amount of remaining blade side shift needed if any and (3) the detected steering angle ⁇ .
  • these goals are enforced in order. For example, an articulation adjustment needed to avoid having the rear wheels impact the curb will take priority over any adjustments needed to provide additional blade side shift or to cause the front and rear wheels to track. Moreover, if no risk of curb impact is apparent, any adjustment needed to provide additional blade side shift will take priority over adjustments needed to cause the front and rear wheels to track. Finally, if articulation adjustments are not needed to avoid curb impact or to provide side shift, then articulation adjustment to allow the wheels to track may be made.
  • a warning or indicator may be provided for the operator when articulation is being actively changed by the controller 94 .
  • the controller 94 may additionally adjust the blade circle shift to provide additional range of blade side movement.
  • the manner of linking the detected steering angle ⁇ to a desired articulation angle a for wheel tracking may be executed via any suitable method.
  • the process described in U.S. Patent Application Publication No. 20110035109 controls articulation based on steering angle in a manner such that a rear centerline point will track a front centerline point.
  • other types of steering-based articulation control may be used instead depending upon the implementation environment. For example, rather than tracking front wheel steering, articulation may be used to accentuate or dampen steering inputs.
  • the controller 94 determines at stage 184 whether the operator has steered the machine 10 out of range of the marker, and lifts the blade 30 and reverts to manual control at stage 186 if this has occurred. Otherwise, the process 160 loops back to stage 174 to reevaluate and refine blade position as the machine 10 moves forward. Even without movement of the blade 30 itself relative to the machine 10 , it will be appreciated that changes in blade position relative to the marker may occur because of machine movement due to steering and articulation and/or because of lateral variations in the position of the marker.
  • the controller 94 adjusts frame articulation and blade position in conjunction with one another rather than adjusting these variables sequentially, based on marker trends and/or upcoming marker features such as curvature of the marker. For example, if the blade edge is detected to be too far from the curb or other marker, the controller 94 may determine whether the marker curves within an upcoming predetermined distance such as a machine length, 30 feet, or other desired measure. If the marker does curve within the established distance, the controller 94 may wait to receive an anticipated steering change and may then use articulation adjustment in conjunction with blade shift to close the gap between the blade edge and the marker to the appropriate distance.
  • an upcoming predetermined distance such as a machine length, 30 feet, or other desired measure.
  • the controller 94 may utilize frame articulation and blade shift to balance one another to allow the greatest remaining freedom of adjustment as the machine 10 continues forward. For example, if the current blade shift position is far off center and nearing a travel limit to the left or right, the controller 94 may readjust the blade shift toward the center while adjusting the frame articulation to account for the altered blade edge position relative to the marker.
  • the controller 94 may shift the blade 30 back toward center while reducing the articulation, with the result that the gap between the blade edge and the marker remains as desired.
  • the operator may steer so far from the marker that the full range of blade shift and frame articulation are not sufficient to keep the gap at the appropriate measure.
  • the controller 94 may consider the machine 10 to be out of range and may terminate the selected automation process.
  • stage 154 directs the process 150 to jump point C, then fully automatic control has been selected, and the controller 94 executes the process 188 shown in FIG. 8 .
  • fully automatic control entails control of machine blade side shift, front wheel steering and rear frame articulation (herein “articulation”) to maintain a set gap to the curb or other marker.
  • machine speed may optionally be controlled to remain below a predetermined set point.
  • the process 188 may require a check of machine speed prior to beginning as discussed with respect to other embodiments above.
  • the controller 94 In executing the process 188 , the controller 94 initially receives a marker sensor position signal or determines an appropriate direction for the marker sensor and positions the marker sensor automatically at stage 190 as discussed above. At this time, the controller 94 may prompt the operator via a visual display to set blade tip, blade circle angle, and optionally to set an appropriate gap between the blade and the curb or other marker, e.g., via a display driven process as discussed above.
  • the controller 94 determines the distance from the blade 30 to the detected marker at stage 192 and moves the blade 30 at stage 194 to the extent needed so that the distance from the blade edge to the marker matches the preset blade gap distance if the user has not manually set the gap and to the extent that such movement does not violate a preset range limit
  • the controller 94 maintains the gap initially set between the blade 30 and the selected curve primarily by adjusting blade side shift via the blade side shift cylinder 53 and/or the center shift cylinder 40 at stage 194 . If the blade shift is limited to less than the actual available range of blade side shift as discussed above, then any unmet side shift requirement may be accommodated in the later steps. In this embodiment, a warning indicator may be provided when the side shift reaches the preset limit value.
  • the controller 94 controls the machine steering angle ⁇ and frame articulation angle ⁇ to provide any additional side shift to the extent such is compatible with any rules of motion such as disallowing impact of the rear wheels on the curb or other marker.
  • the controller 94 adjusts the steering angle and articulation angle to move the machine 10 closer to or farther away from the curb in order to assist in maintaining the gap at the desired value while also keeping the blade side shift within an acceptable range, to the extent the adjustment does not violate a rule of motion.
  • the desired distance range between the front and rear tires to the target curve to be graded may be maintained by adjusting the steering angle and the articulation angle.
  • the relationship between the steering angle ⁇ and articulation angle ⁇ may be specified in any desired manner, but in an embodiment, steering and articulation angles are set such that a rear centerline point will track a front centerline point as discussed above. If the articulation available within the above limits is not sufficient to allow the blade 30 to continue tracking the curve without violating a restriction as noted above, the controller 94 may additionally adjust the blade circle shift to provide additional range of blade side movement.
  • the controller 94 adjusts steering angle and frame articulation angle in concert at stage 198 to follow the target curve. If the curve ends as determined at stage 200 (except for momentary termination with an expected resumption, e.g., after a gap) or if the user manually terminates the automatic control process as determined at stage 202 , then the process 188 ends. Otherwise, the process 188 continues to execute stage 198 in order to follow the target curve.
  • the controller 94 may control the machine speed during any automated mode, e.g., to maintain a constant speed in addition to ensuring that machine speed is less than a predetermined threshold speed.
  • automatic speed control may be useful during operations in environments having frequent grade changes.
  • the controller 94 exits any automatic blade gap setting mode in the event that the operator either attempts to control an automated or fixed function such as blade depth or shift, or manipulates a manual control, such as steering, to the extent that the machine 10 is placed beyond an automatically correctable range. Similarly, if the operator at any time switches from an automatic mode into manual mode, the controller 94 returns the machine 10 to manual control. In a further embodiment, the controller 94 causes the blade 30 to be lifted when switching out of any automatic mode into manual mode.
  • FIG. 9 illustrates a display usable to show the blade-curb gap the operator and to allow the operator to appropriately set the gap. It will be appreciated that the same display can also be used to show the blade tracking the curb in real time as the motor grader progresses forward.
  • the system may display a map or worksite diagram, referred to herein as a record image 230 , showing areas that have, and have not been, graded.
  • the record image 230 may be displayed at a different time, e.g., later, than other images discussed herein or may be displayed simultaneously, e.g., via a split screen.
  • the graded portion 232 of the worksite is shown via a distinct shading on the worksite diagram 230 .
  • the graded portion 232 may alternatively be indicated by another static indicator such as color or intensity of illumination, or by a dynamic indicator such as blinking.
  • the worksite diagram 230 may also be used to delineate areas in which the set blade-curb gap was not maintained (“nonconforming portions”), for example due to slippage or jolting of the machine 10 or due to the operator temporarily taking the machine 10 out of range.
  • nonconforming portions areas in which the set blade-curb gap was not maintained.
  • the area in which the blade-curb gap was not maintained is indicated by box 234 .
  • Other ways of indicating the error are possible, including distinguishing the affected area of the worksite diagram 230 by distinct coloring, shading, or other distinctive indicator.
  • display controls 236 are provided in an embodiment.
  • the display controls 236 include panning controls 238 as well as “zoom in” control 240 and a “zoom out” control” 242 .
  • the present disclosure sets forth a system and method for control of a motor grader during operations that track a roadway marker such as a curb.
  • the system and method control one or more aspects of the motor grader operation during grading near a cul-de-sac curb.
  • a machine operator may select a mode of operation, with exemplary modes of operation including a manual mode, a blade automation mode, a blade and steering automation mode, and a full auto mode wherein blade shift, machine steering, and machine articulation are automated to track the marker.
  • the operator may change modes or, in an embodiment, simply control the machine out of a current automated mode, in which case the machine reverts to the manual mode.
  • the method and system for motor grader operation described herein maintain a desired gap between the blade and the marker to prevent the motor grader blade from impacting the marker during operation, especially during operations adjacent curved markers such as cul-de-sac curbs.
  • the distance data gathered in this process can also be used in a historical manner to provide a record of a grading process.
  • the data are used in an embodiment to provide the operator with a map of areas that have been graded with the desired gap, i.e., what areas have been traversed with blade control engaged.
  • This record may be optionally superimposed on a site map to provide an operator or supervisor with a record of work done and a representation of work yet to be done.
  • the display includes one or more indicators showing areas that experienced issues to be corrected or noted, such as areas where the gap-to-curb setting was violated.
  • the present disclosure provides an effective and efficient mechanism and control system for motor grader control. Not only do the described system and method generally improve operator comfort and reduce operator fatigue, but they also yield a high-quality grading product with less operator training and experience than might otherwise be required.

Abstract

A method, controller and system in accordance with various aspects of the present disclosure provide display-based control of a motor grader for grading near a curb or other roadway marker. A blade image is displayed to the operator on a display screen showing a portion of the blade and a portion of the curb or marker, and input is received from the operator to move the blade such that a gap between the portion of the blade and the portion of the curb conforms to a target distance. The gap between the portion of the blade and the portion of the curb is monitored as the motor grader moves along the curb and the location of the blade relative to the curb is automatically adjusted such that the gap remains at the target distance. The blade image may be updated as the motor grader proceeds along the curb.

Description

    TECHNICAL FIELD OF THE DISCLOSURE
  • The present disclosure relates to motor grader operation and, more particularly, relates to motor grader blade and steering control for operations near roadway markers such as curbs.
  • BACKGROUND OF THE DISCLOSURE
  • Motor graders are earth-moving machines that are employed in a variety of tasks, including as shaping tools to create banks, ditches, and berms, as surface preparation tools for scarification and other surface treatments, and as finishing tools to refine construction site and roadway surfaces to final shape and contour. Although not universally applicable, motor graders typically include a front frame and a rear frame that are joined at an articulation joint. The rear frame includes compartments for housing the power source and cooling components, the power source being operatively coupled to the rear wheels for primary propulsion of the machine. The rear wheels are typically arranged in tandem sets on opposing sides of the rear frame. The front frame typically includes a pair of front wheels, and supports an operator station and a blade assembly.
  • In order to create a desired shape, contour, and/or finish, the motor grader blade can generally be rotated, tilted, raised, lowered, and/or shifted side to side to any of a large number of positions with fine resolution of motion. Thus, although the blade is affixed to the motor grader, the relative blade position is highly variable.
  • Overall steering of the machine is generally a function of both front wheel steering (typically referred to as “steering”) and articulation of the front frame relative to the rear frame (typically referred to as “articulation”). This allows the machine to navigate relatively tight arcs and circles such as may occur at curves or turns in a roadway. Given the ability to control the blade position, frame articulation, and wheel steering, the operation of a motor grader presents users with a complex task. The operator interface to control the machine generally includes various hand-operated controls to steer the front wheels, position the blade, control frame articulation, and control auxiliary devices such as rippers and plows, while also including various displays for monitoring machine conditions and/or functions.
  • During tasks that require fine blade and machine positioning, even experienced operators will often need to slow down the pace of operation to avoid damaging the roadway or impacting nearby markers, while ensuring that the blade reaches the limits of the area to be treated. As used herein, the term “marker” refers to a structure to be followed such as a curb. While a marker need not be specifically marked with a visible paint or other marking substance, the term “marker” does not exclude such visually marked structures.
  • In cul-de-sac grading, the operator is required to maneuver the motor grader around a tightly curved path while maintaining the blade at a desired distance from curbs and other obstacles. This requires that the operator simultaneously control the blade, front wheel steering and frame articulation angle. Failure to properly control any one of these variables in such circumstances can result in blade-obstacle collisions or incomplete grading.
  • Certain systems seek to address portions of this problem. For example, U.S. Appl. No. 2010/0010703 to Coats et al. discloses a method for machine guidance that is directed to maintaining a machine position relative to a marker. While the system of Coats et al. does assist operators by automating certain machine positioning tasks, it does not address blade positioning for sensitive operations such as cul-de-sac grading and contouring.
  • The present disclosure is directed to a machine control system and method to improve motor grader operations in order to address one or more of the problems or shortcomings set forth above. However, it should be appreciated that the solution of any particular problem is not a limitation on the scope of this disclosure and the attached claims except to the extent expressly noted. Additionally, this background section discusses problems and solutions noted by the inventors; the inclusion of any problem or solution in this section is not an indication that the problem or solution represents known prior art except as otherwise expressly noted. With respect to prior art that is expressly noted as such, the summary thereof is not intended to alter or supplement the prior art document itself; any discrepancy or difference should be resolved by reference to the prior art.
  • SUMMARY OF THE DISCLOSURE
  • In accordance with one aspect of the present disclosure, a method of controlling a motor grader is provided. The motor grader has a blade for grading an underlying surface, and the method includes displaying a blade image on a display screen to an operator of the motor grader, the blade image having a representation of at least a portion of the blade and at least a portion of a curb adjacent the motor grader. Input is received from the operator to move the blade such that a gap between the portion of the blade and the portion of the curb conforms to a target distance. The gap between the portion of the blade and the portion of the curb is monitored as the motor grader moves along the curb and the location of the blade relative to the curb is adjusted such that the gap remains at the target distance. The blade image is updated as the motor grader moves along the curb.
  • In accordance with another aspect of the present disclosure, a controller is provided for providing display-based control of a motor grader having a blade for grading an underlying surface. The controller includes computer-executable instructions on a computer-readable medium for displaying a blade image on a display screen to an operator of the motor grader, the blade image having a representation of at least a portion of the blade and at least a portion of a curb adjacent the motor grader. Instructions are included for receiving an input from the operator to move the blade such that a gap between the portion of the blade and the portion of the curb conforms to a target distance and for monitoring the gap as the motor grader moves along the curb and adjusting the location of the blade relative to the curb such that the gap continues to conform to the target distance. The instructions also include instructions for updating the blade image as the motor grader moves along the curb.
  • In accordance with yet another aspect of the disclosure, a system is provided for controlling a motor grader during grading near a curb, the motor grader having a blade for grading an underlying surface. The system includes a display for displaying to an operator of the motor grader an image showing a gap between the blade and the curb and for receiving user input to alter the gap to a target distance. A controller is configured to adjust a position of the blade during grading of the underlying surface to maintain the gap between the blade and the curb at the target distance.
  • Additional and alternative features and aspects of the disclosed methods and systems will become apparent from reading the detailed specification in conjunction with the included drawing figures.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a pictorial representation of a side view of an exemplary motor grader;
  • FIG. 2 is a pictorial representation of a top view of an exemplary motor grader;
  • FIG. 3 is a diagrammatic illustration of a top view of an exemplary motor grader illustrating steering and articulation angles;
  • FIG. 4 is a control schematic showing controller inputs and outputs used in implementing various embodiments of the disclosed systems and methods;
  • FIG. 5 is a flow chart illustrating an overview process for operation of certain aspects of a motor grader machine based on a mode selection by the operator;
  • FIG. 6 is a flow chart illustrating an automatic blade control process in accordance with one implementation of the disclosure;
  • FIG. 7 is a flow chart illustrating an automatic blade and articulation control process in accordance with one implementation of the disclosure;
  • FIG. 8 is a flow chart illustrating an automatic blade, steering, and articulation control process in accordance with one implementation of the disclosure;
  • FIG. 9 is a schematic example of a display or “blade image” for allowing user selection of certain parameters; and
  • FIG. 10 is a record image display of a worksite showing areas that have and have not been graded according to an aspect of the disclosure.
  • DETAILED DESCRIPTION OF THE DISCLOSURE
  • The present disclosure provides a system and method for motor grader steering and blade control for operations relative to roadway markers such as, but not limited to, curbs and the like. Referring now to FIG. 1 and FIG. 2, there is shown an exemplary motor grader in accordance with one embodiment of the present disclosure. The illustrated motor grader 10 includes a front frame 12, rear frame 14, and a work implement 16. In the context of a motor grader, the work implement 16 is typically a blade assembly 18, also sometimes referred to as a drawbar-circle-moldboard assembly (DCM). The blade assembly 18 may include a separate blade portion and a moldboard portion, and such arrangements will be referred to herein collectively as the blade, moldboard, or DCM.
  • The rear frame 14 includes a power source, not shown, contained within a rear compartment 20. The power source is typically operatively coupled through a transmission, not shown, to rear traction devices or wheels 22 for primary machine propulsion. As shown, the rear wheels 22 are operatively supported on tandems 24 which are pivotally connected to the machine between the rear wheels 22 on each side of the motor grader 10. The power source may be, for example, a diesel engine, a gasoline engine, a natural gas engine, or any other engine known in the art. The power source may additionally or alternatively comprise a battery, fuel cell or other electrical power storage device known in the art. The transmission may be a mechanical transmission, hydraulic transmission, or any other transmission type known in the art and may be operable to produce multiple output speed ratios (or a continuously variable speed ratio) between the power source and driven traction devices.
  • The front frame 12 supports an operator station 26 containing various operator controls, along with a variety of displays or indicators used to convey information to the operator, used for primary operation of the motor grader 10. The front frame 12 also includes a beam 28 that supports the blade assembly 18. The blade assembly 18 includes a drawbar 32 pivotally mounted to a first end 34 of the beam 28 via a ball joint (not shown). The position of the drawbar 32 is controlled by three hydraulic cylinders: a right lift cylinder 36 and left lift cylinder 38 that control vertical movement, and a center shift cylinder 40 that controls horizontal movement. The blade 30 may be shifted sideways relative to the front frame 12 via shifting of the blade 30 itself or via shifting of the drawbar 32.
  • The right and left lift cylinders 36, 38 are connected to a coupling 70 that includes lift arms 72 pivotally connected to the beam 28 for rotation about axis C. A bottom portion of the coupling 70 has an adjustable length horizontal member 74 that is connected to the center shift cylinder 40.
  • The drawbar 32 includes a large, flat plate, commonly referred to as a yoke plate 42. Beneath the yoke plate 42 is a circular gear arrangement and mount, commonly referred to as the circle 44. The circle 44 is rotated by, for example, a hydraulic motor referred to as the circle drive 46. In other embodiments, an electric motor is used to facilitate rotation of the circle 44.
  • Whatever the technology used to drive the circle drive 46, rotation of the circle 44 by the circle drive 46 rotates the attached blade 30 about an axis A perpendicular to a plane of the drawbar yoke plate 42. As used herein, the blade circle angle refers to the angle of the blade 16 relative to a longitudinal axis 48 of the front frame 12. For example, at a zero degree blade circle angle, the blade 30 is aligned across the machine 10 at a right angle to the longitudinal axis 48 of the front frame 12 and beam 28, as shown in FIG. 2.
  • A pivot assembly 50 between the blade 30 and the circle 44 allows for tilting of the blade 30 relative to the circle 44. To this end, a blade tip cylinder 52 is used to tilt the blade 30 forward or rearward. In other words, the blade tip cylinder 52 is used to tip or tilt a top edge 54 relative to the bottom cutting edge 56 of the blade 30, and the occurrence or extent of this tilting is commonly referred to as blade “tip.” The blade 30 can be shifted to the left or right by the blade side shift cylinder 53 along directions D.
  • As noted above, steering of the motor grader 10 is accomplished through a combination of front wheel steering and machine articulation. As shown in FIG. 2, steerable traction devices (right wheel 58 and left wheel 60 in the illustrated example) are associated with the first end 34 of the beam 28. The right wheel 58 and left wheel 60 may be rotatable and tiltable for use during steering and leveling of a work surface 86. The right wheel 58 and left wheel 60 are connected via a steering apparatus 88 that may include a tie rod 90 for pivoting the wheels in unison about pivot points 80 as well as one or more wheel tilt actuators 91 to provide front wheel tilt.
  • Referring to FIGS. 1 and 3, the motor grader 10 includes an articulation joint 62 that pivotally connects front frame 12 and rear frame 14 at an articulation axis B. Both a right articulation cylinder 64 and a left articulation cylinder 66 are connected between the front frame 12 and the rear frame 14 on opposing sides of the machine 10. The right and left articulation cylinders 64, 66 are used to pivot the front frame 12 relative to the rear frame 14, separated at articulation axis B. In the illustrative example of FIG. 2, the motor grader 10 is positioned in the neutral or zero articulation angle position wherein the longitudinal axis 48 of the front frame 12 is aligned with a longitudinal axis 68 of the rear frame 14.
  • FIG. 3 provides a top view of the motor grader 10 with the front frame 12 rotated at an articulation angle α defined by the intersection of longitudinal axis 48 of front frame 12 and longitudinal axis 68 of the rear frame 14, the intersection corresponding with the position of articulation joint 62. This illustration follows the convention that a positive a value is indicative of a left articulation from the perspective of an operator facing forward, while a negative a value would be indicative of a right articulation. A front wheel steering angle θ is defined between a longitudinal axis 76 parallel to the longitudinal axis 48 of front frame 12, and a longitudinal axis 78 of the front wheels 58, 60, the angle θ having an origin at the pivot point 80 of the front wheels 58, 60. This is demonstrated in connection with left front wheel 60, but also applies to the right front wheel 58. It will be appreciated that in order for the turn centers of the front wheels 58, 60 to coincide as shown, one may have a slightly different steering angle from the other, with the outside wheel generally having a longer radius.
  • As can be seen, the motor grader 10 has many degrees of freedom, both in steering and in blade position, that provide the ability to perform precise work; however, these various degrees of freedom must be carefully controlled to provide the best work product and operator experience. As noted above, cul-de-sac operations can be especially challenging, given the need to precisely steer the motor grader 10 while simultaneously positioning the blade assembly 18 with sufficient accuracy, particularly in the shift dimension, to avoid curb damage or incomplete grading.
  • In an embodiment of the disclosure, a number of special machine modes are provided including an automatic blade mode wherein the blade assembly 18 is automatically positioned relative to a road marker such as a curb or roadway edge while the operator controls the positioning of the machine 10 via steering and articulation. In a further embodiment, machine articulation is automated as well, such that the articulation and blade shift are controlled cooperatively to maintain a desired spacing between the edge of the blade assembly 18 and the marker. In yet another embodiment, a fully automated mode provides automatic control of blade side shift, frame articulation, and wheel steering. As an optional aspect of one or modes, machine speed may be controlled or limited. These various modes ease the chore of cul-de-sac grading near curbs and enhance work product uniformity during long stretches of straight-line grading near a road edge or curb.
  • Referring to FIG. 4, although other physical implementations are possible, an embodiment of the disclosure employs a controller 94 for receiving and evaluating machine commands such as mode selections. The controller 94 is also configured to receive and evaluate machine data, such as steering angle, blade angle, blade shift, blade tilt, machine speed, etc. In addition, the controller 94 may receive and evaluate sensor data, such as the location of the roadway marker adjacent the machine, the curvature of, or downrange points on, the marker, and so on. The controller 94 also provides data and control outputs as needed to execute the methodology described herein depending upon the mode selected, e.g., setting the shift of the blade assembly 18, setting the steering and tilt angle of one or more machine wheels, setting the angle of articulation, etc.
  • The controller 94 is implemented, in an embodiment, as a computing device incorporating one or more microcontrollers and/or microprocessors (collectively referred to herein as a “processor” or “digital processor”). The controller 94 operates by reading or loading computer-executable instructions, or code, from a nontransitory computer-readable medium such as a nonvolatile memory, a magnetic or optical disc memory, a flash drive, and so on. To the extent that the read instructions are associated with and accessible to the controller 94, the controller 94 may be said to include such instructions.
  • The controller 94 may execute the instructions in a time-shared manner, a multi-thread manner, or any other suitable execution technique. It will be appreciated that data used by the controller 94 in the execution of the computer-executable instructions may be stored and read out as well, or may be created in real time. The controller 94 has one or more interfaces to receive data and/or commands, and one or more outputs to output data and/or commands such as those discussed above. The controller 94 may be an isolated controller or is alternatively implemented within another controller that also serves other machine functions.
  • In the illustrative embodiment shown in FIG. 4, the controller 94 receives a steering angle sensor input signal 96 from one or more steering angle sensors 98. This steering angle sensor input signal 96 provides a signal indicative of the steering angle. As used herein, a signal is indicative of a specified quantity or value when it directly or indirectly conveys or can be used to calculate, directly or indirectly, that quantity or value. With respect to all inputs, it will be appreciated that each signal may be communicated over a dedicated physical line or channel, or may be multiplexed over a multi-signal channel, as may be the case in the event that the machine 10 utilized a managed machine area network. In either case, one or more input signals may be communicated at least partially by wireless transmission.
  • The controller 94 further receives a steering input signal 100 from one or more operator steering controls 102 indicative of an operator steering command. Alternatively, the steering input signal is received from steering angle sensors 98. The operator steering controls 102 may include a joy stick as shown in FIGS. 1-2, or any other type of operator input device, such as a dial, keyboard, pedal or other devices known in the art. In one embodiment a steering angle sensor is configured to sense the rotation or position of the operator steering controls 102 and to provide a steering input signal 100 indicative of a steering angle θ.
  • In an embodiment, the controller 94 further receives an articulation input signal 104 from one or more articulation sensors 106, with the articulation input signal 104 being indicative of the articulation angle α at the axis B between the rear frame 14 and front frame 12. In a further embodiment, the one or more articulation sensors 106 include a pivot sensor disposed at articulation joint 62 to sense rotation about articulation axis B. Additionally or alternatively, the one or more articulation sensors 106 may include one or more sensors configured to monitor the extension of right and/or left articulation cylinders 64, 66. It will appreciated that the steering angle sensors 98, steering wheel sensor (at operator steering controls 102), articulation sensors 106, as well as other sensors for rotational movement may be, for example, potentiometers, extension sensors, proximity sensors, angle sensors, rotary encoders, and the like.
  • In an embodiment, one or more blade position sensors 110 provide a blade position input signal 108 to the controller 94, the blade position input signal 108 being indicative of the actual position of the blade 30. Such sensors may be configured to sense blade position directly or may be configured to sense blade position indirectly (for example from pin angle sensors, etc.) based on the positions of the related hydraulic actuators. In an embodiment, the blade position in at least the shift direction is sensed via a non-contact sensor (“object sensor”), e.g., digital camera, LADAR, LIDAR, etc. The blade position input signal 108 may also indicate a position of the blade 30 in other dimensions as well, such as tilt, tip, and rotation.
  • Similarly, a blade position command input signal 124 originating from an operator blade positioning input device 126 provides the controller 94 with information regarding an operator's inputs to position the blade 30. The operator blade positioning input device 126 may be any suitable operator control for setting blade position, including but not limited to one or more joysticks, levers, and the like.
  • One or more transmission sensors 114 may be used, associated with the transmission, to provide a gear input signal 112 indicative of a current gear or output ratio associated with the machine transmission. Alternatively, the gear input signal 112 may be provided by signals associated with operator controls for the transmission (not shown).
  • Although the machine configuration can be known from the above referenced data inputs to the controller 94, the position of the machine and blade relative to a roadway marker such as a curb cannot be discerned from these inputs other than perhaps by extrapolation from a past known relationship. To this end, in order to provide real time information regarding the location of a marker adjacent the machine 10 and/or ahead of the machine 10, one or more marker sensors 118 (“object sensors”) provide a marker position input signal 116 to the controller 94. In an embodiment, the one or more marker sensors 118 include only a single sensor, which is selectively directed to one side of the machine 10 or the other depending upon which side of the machine 10 the roadway marker is known or detected to be located.
  • Additionally or alternatively, the one or more marker sensors 118 may include multiple stationary sensors or a more limited number of scanning sensors, or a combination of stationary and scanning sensors. A scanning sensor in this context is one that can be dynamically directed to a different field of view, e.g., it may be selectively directed forward or sideways, downward or sideways, left side or right side, etc. In addition, virtual sensor arrays may be implemented from a single sensor via synthetic array heterodyne detection schemes and the like to enhance the capabilities of individual sensors.
  • The one or more marker sensors 118 may include one or more LIDAR (light detection and ranging) sensors, one or more LADAR (laser detection and ranging) sensors, one or more digital cameras, and/or other types of sensors. It will be appreciated that LIDAR sensing involves the emission and detection of UV, visible or near infrared radiation to determine a distance between the sensor and a target object, e.g., the roadway marker. Similarly, LADAR involves the use of laser radiation to detect the distance to the target object. In addition to employing coherent radiation instead of the non-coherent radiation used in LIDAR, LADAR may also operate in areas of the electromagnetic spectrum not used by LIDAR.
  • While LADAR can generally provide better long range accuracy than LIDAR, the systems and processes of this disclosure entail short range detection. Similarly, cameras typically provide accurate ranging information only at short ranges relative to both LADAR and LIDAR, but cameras do provide suitable ranging capabilities within the close ranges contemplated herein. As such, the selection of sensor type, number, and position may be resolved by issues of cost and availability as well as any considerations of multi-purposing of sensors rather than questions of efficacy. For example, a single sensor may be used for both object detection and personnel detection, or for other additional purposes.
  • In an embodiment, all or a subset of the one or more marker sensors 118 in conjunction with the processor may be configured to preferentially detect a specific marking, material, or quality associated with the roadway marker. For example, a curb can be characterized by a longitudinal block of a certain color or color range bounded by linear boundaries to other colors such as the color of soil, grass, etc.
  • In environments where the linear character of the curb is not discernable or the color of the curb is too close to the colors of other surfaces bounding the curb, a non-naturally occurring color may be applied to the curb to provide a signal for the one or more marker sensors 118 to preferentially detect. For example, a continuous stripe of bright white or neon orange paint may be applied to the curb to aid in detection and/or ranging. In this embodiment, the detected non-naturally occurring color would identify a target, e.g., the curb, upon which ranging occurs.
  • In an embodiment, a propulsion input signal 120 is provided to the controller 94 from one or more operator-controlled propulsion interface devices 122, e.g., acceleration pedals or levers, transmission mode selectors, etc. Such interface devices 122 may be located in the operator station 26. An engine speed input signal 121 is also provided to the controller 94 in an embodiment, with the associated engine speed data originating from an RPM sensor 123 or the like.
  • A machine position sensor cluster 130 is configured to provide the controller 94 with a machine position input signal 128. The machine position sensor cluster 130 may include without limitation one or more accelerometers, inclinometers, inertial measurement units, and other orientation sensors, as well as a GPS or other positioning system. As such, the machine position input signal 128 provides the controller 94 with information regarding both the position and orientation of the machine 10.
  • As noted above, a mode selection option for the operator is enabled in an embodiment of the disclosure. The mode selection option may be presented via a mode selector switch 134 which provides a mode selection signal 132 to the controller 94. As will be discussed in greater detail below, the mode selector switch 134 may be employed to select amongst various modes of operation including, for example, a blade automation mode, a blade and articulation automation mode, a full auto mode and a normal or manual mode.
  • Before discussing these modes and the operation and configuration of the controller 94 to implement operations in the various modes, exemplary outputs of the controller 94 will be briefly identified and discussed. It will be appreciated that each output signal may be provided over a dedicated physical line or channel, or all outputs may be multiplexed over a lesser number of non-dedicated lines or channels. Moreover, one or more outputs may be communicated at least partially by wireless transmission.
  • In order to maintain machine position for modes requiring such, the controller 94 provides a steering output 136 to set the steering angle of the front wheels of the machine 10. The steering output 136 may be provided to a system controller that implements the steering command. By way of example, the steering output 136 may be provided to and processed by the same logic and hardware that process the steering commands from the operator steering controls, which further actuates hydraulic cylinders (not shown) of the steering apparatus 88 so as to implement the steering command. As will be discussed later, the steering output 136 may be overridden by the operator in an embodiment.
  • For controlling the articulation of the machine 10 when in a mode requiring such control, the controller 94 provides an articulation output 138. As with other outputs, the articulation output 138 may be provided to another controller or subsystem responsible for implementing articulation commands. Alternatively, the articulation output 138 may be implemented via independent hardware and processing. In either case, the indicated articulation command is used to control machine frame articulation, e.g., via the articulation actuators 64, 66.
  • In order to control the position of the blade 30 to maintain distance between the blade and the roadway marker during operations (“target distance”), the controller 94 provides a blade shift output 140. The blade shift output 140 may be provided to a control solenoid associated with a hydraulic control valve for the blade side shift cylinder 53 and/or the center shift cylinder 40 via the same hardware as the operator-input shift commands or via an independent channel or circuitry.
  • Finally, in some modes it may be desirable to control machine speed. To this end, the controller 94 provides a machine speed output 142. The machine speed output 142 may contain, or may be used to generate, commands for controlling machine engine speed, drive speed, and/or transmission mode or range. For example, for rough ground conditions, it may desirable to maintain a constant torque at the traction elements, whereas in an environment having significant gradient variation, it may be desired to maintain a constant machine speed.
  • It will be appreciated that other inputs and outputs may be linked to the controller 94 in a traditional manner, and such are not itemized and illustrated herein. For example, it will be appreciated that the controller 94 outputs a display signal to a display screen in keeping with the display features and aspects discussed herein. Although such images are novel, the way in which the controller 94 causes a given image to be displayed will be known to those of skill in the art.
  • Exemplary processes utilized by the controller 94 in an embodiment to control blade distance to the roadway marker in various modes are shown in FIGS. 5-8. While the disclosure will exemplify these processes as being executed by the controller 94, it will be appreciated that the processes may be distributed as needed or desired in a given implementation. Moreover, it will be appreciated that the order of steps within each process is illustrative, and the steps need not occur in the given order unless otherwise apparent from the disclosure. Moreover, while the disclosure explains operations in various selectable modes, it is also contemplated, without departing from the scope of these teachings, for a machine in a particular implementation to support only a subset of the described modes, or indeed, to support only a single mode.
  • Referring now to FIG. 5, an overview process 150 is shown for operation of certain aspects of the machine based on a mode selection by the operator, e.g., by way of the mode selector switch 134. The process 150 is used in order to identify further processes for execution based on mode selection. At stage 152 of the process 150, the controller 94 receives a mode selection signal from the mode selector switch 134. The mode selection signal identifies a desired mode of operation, selected from among available modes, e.g., manual, automatic blade control, automatic blade and articulation control, and fully automatic control.
  • In the illustrated embodiment, the process 150 determines subsequently at stage 154 which of the available modes has been selected, and terminates if manual operation has been selected, continues to jump point A (see FIG. 6) if automatic blade control has been selected, continues to jump point B (see FIG. 7) if automatic blade and articulation control has been selected, and continues to jump point C (see FIG. 8) if fully automatic control has been selected. In an optional embodiment, the modes other than the manual mode may be locked out, i.e., not selectable, if the machine speed is higher than a predetermined acceptable speed.
  • Turning to FIG. 6, an automatic blade control process 160 is shown. The automatic blade control process 160 is entered at jump point A, and begins with optional stage 162, wherein the controller 94 receives a marker sensor position signal, e.g., an indication of whether a marker sensor such as a camera, LIDAR sensor, or other marker sensor is facing to the left of the machine 10 or to the right. Alternatively, the controller 94 may determine an appropriate direction for the marker sensor and position the marker sensor automatically.
  • For example, when an automatic mode is selected, in an embodiment having a single sensor, the controller 94 can scan the sensor on a first side of the machine 10, e.g., the right side, for a curb or other marker, and if one is found, maintain the sensor in that orientation. If a curb or other marker is not found in a scan of the right side, the controller 94 may then scan the sensor on the opposite side of the machine 10. In an embodiment wherein separate left and right facing sensors are used, the marker sensor position signal may indicate which marker sensor is to be active, e.g., on which side of the machine 10 the marker has been detected. In an alternative embodiment, the operator selects which sensor is to be active or which direction a single sensor is to face.
  • Prior to proceeding in the process 160, the controller 94 may prompt the operator via a visual display to set certain aspects of the blade positioning to the desired setting, e.g., to set a desired blade tip, tilt, and circle shift. Having determined the marker sensor position, the process 160 flows to stage 164, wherein the controller 94 determines the distance from the blade 30 to the detected marker, e.g., the curb or other marker. While a given sensor such as a camera, LIDAR sensor, LADAR sensor, etc. will typically only determine the distance between the sensor itself and the marker, the controller 94 may then process that distance information given the known sensor position relative to the machine and the known blade position relative to the machine to determine the distance from the blade edge to the marker.
  • In an embodiment, the detected marker structure may be displayed to the user, who then selects which feature to follow. For example, a square curb may have four or more linear features including those in the base, and the user can select a feature of the displayed structure against which distance is to be measured. In an alternative embodiment, the operator is also prompted to set an acceptable blade gap. For example, the operator may be shown a camera view of the blade and marker on a display and may set a gap on the screen visually or numerically, or may manually shift the blade while watching the display until the desired gap is achieved. Alternatively, the operator is prompted to confirm the closest feature. In a further alternative, the operator is prompted to input a distance value.
  • A schematic example of a display for allowing user selection of parameters is shown in FIG. 9. This image is referred to herein as a blade image, and in general shows at least a portion of a curb adjacent the motor grader 10 and at least a portion of the blade 30 so that the operator may visualize the gap and in some embodiments adjust the gap via the display in the case of a touch screen display. The blade image may be photographic, e.g., showing data gathered by a camera aimed at the area including a portion of the blade and a portion of the curb, or may be computer generated as in the illustrated example.
  • The illustrated selection display 206 shows the detected linear features of a curb 208 in cross-section as curb point A (210), curb point B (212) and curb point C (214). In an embodiment, a marking such as a bright paint may be applied to the curb, either along the entire length to be tracked or periodically, to enhance the ability of the sensor to detect and distinguish the curb or certain features of the curb.
  • Each curb point 210, 212, 214 is associated with a tracking curve, i.e., tracking curve A (216), tracking curve B (218), and tracking curve C (220). The blade 30 is represented in the display 206 by blade outline 222. In an embodiment, the display 206 includes one or more parameter fields allowing the operator to enter desired parameters. In the illustrated embodiment, the display 206 includes a blade gap field 224 in which the operator may enter a numerical blade gap, as well as a finish selection field 226 for selection when finished setting the gap. As noted above, the user may also set the blade gap manually while watching the display 206 or, in a further embodiment, may set the gap by manipulating the display itself via a cursor selection or touch screen operation.
  • In selecting a curb point to measure against, the operator also selects the corresponding tracking curve in an embodiment. Because the mechanisms associated with the blade 30 cannot react instantaneously, the curve allows the controller 94 to predict and accommodate upcoming curves and discontinuities. In this connection, note that the tracking curves 216, 218, 220 need not precisely track the selected curb point. Rather, a tracking curve may be interpolated across minor gaps or discontinuities of a particular curb point, such as a gap for a gutter grate, manhole cover opening, etc.
  • In an embodiment, the interpolated tracking curve during a discontinuity is comprised of a curve segment that connects the last non-interpolated point before the gap and the first non-interpolated point after the gap. The curve segment has a curvature in this embodiment that is substantially the average of the curve values immediately before and immediately after the gap. Local curvatures may be identified by a radius, a polynomial expression, or otherwise.
  • In some cases, the tracking curve may exhibit a termination, i.e., where there is no far side point on the curve visible, instead of a gap where a far side point can be detected. In such cases, when the blade 30 reaches a termination point, the tracking process may fix the blade position at its current position until the curve is again detected, terminate automatic blade control, or shift the blade 30 sideways away from the curb side. Other responses may be appropriate depending upon the implementation environment. For example, if the tracked curb or other marker is known to be circular or to follow some other predefined path, the tracking process may continue to track the virtual known curve even in the absence of a detectable actual curb or other marker.
  • Continuing with the process 160, if the user has not manually set the gap, the controller 94 moves the blade 30 at stage 166 to the extent needed so that the distance from the blade edge to the marker matches a target blade gap distance, which may be as little as about 30 mm or less, depending upon machine resolution of motion, up to much larger gap distances, as may be required when working near curbs having extended base portions. In an embodiment, the target blade gap distance is a preset value, and in an alternative embodiment the operator may select a target distance to be maintained as noted above.
  • At stage 167, as the machine 10 moves forward, the controller 94 maintains the gap between the blade 30 and the selected curve by adjusting blade side shift via the blade side shift cylinder 53 and/or the center shift cylinder 40. In an embodiment, blade side shift is primarily used to adjust the gap, with center shift then being used as needed. The distance from the blade 30 to the selected curve may be accomplished via a combination of both side shift and circle angle adjustment in an embodiment. In one embodiment, the circle angle is pre-determined or pre-set. Alternatively, the operator may elect to manually control this function during the course of operations. In addition to adjusting the gap via the circle angle, in an embodiment the circle angle is automatically controlled to maintain a predetermined angle, or to stay within a predetermined angle range, based a tangent of the marker relative to the circle angle.
  • In an embodiment, the blade shift executed in stage 167 is limited to a predetermined percentage of the range of blade shift available to allow some reserve capacity to shift further if need be. For example, the shift may be limited at stage 167 to 75% of the total available range. A warning indicator is provided, in an embodiment, when the side shift reaches the preset limit value.
  • As the machine 10 proceeds along the marker, the controller determines at stage 169 whether the operator has steered the machine 10 out of range of the marker. If the operator has steered the machine 10 out of range of the marker, then the process 160 lifts the blade at stage 170 and reverts the machine to manual control. If instead it is determined at stage 169 that the operator has not steered the machine 10 out of range of the marker, the process 160 loops back to stage 162 to reevaluate and further refine blade position as the machine 10 moves forward. In an embodiment, a warning may be given before reverting to manual control. For example, a visual or audible warning may indicate that the blade gap distance is in danger of going out of range, that the machine is travelling too fast, etc.
  • In addition to the termination conditions noted above, one or more other conditions may also cause the machine 10 to revert to manual control. For example, in an embodiment, the process 160 is terminated and the machine 10 reverted to manual operation whenever the operator manipulates the blade side shift manually, e.g., via operator controls in the operator station 26.
  • If the automatic blade and articulation control mode was selected at stage 154 of process 150, then the controller 94 operates according to the automatic blade and articulation control process 172 shown in FIG. 7, which is initially similar to the automatic blade control process 160. The process 172 is entered at jump point B, and begins with optional stage 174, wherein the controller 94 receives a marker sensor position signal or determines an appropriate direction for the marker sensor and positions the marker sensor automatically as discussed above. Prior to continuing, the controller 94 may prompt the operator via a visual display to set certain aspects of the blade positioning to the desired setting, e.g., to set a desired blade tip, tilt, and circle shift, as discussed with respect to process 160.
  • The controller 94 then determines the distance from the blade 30 to the detected marker at stage 176 and moves the blade 30 at stage 178 to the extent needed so that the distance from the blade edge to the marker matches the preset blade gap distance if the user has not manually set the gap. As noted above with reference to FIG. 9, in an alternative embodiment, the detected marker structure may be displayed to the user, who then selects which feature to follow and sets an appropriate gap.
  • Subsequently as the machine 10 moves forward, the controller 94 maintains the gap initially set between the blade 30 and the selected curve by adjusting blade side shift via the blade side shift cylinder 53 and/or the center shift cylinder 40 at stage 179. In an embodiment, the blade shift is limited to less than the actual available range of blade side shift, e.g., 75% of the total available range. Again, a warning indicator may be provided when the side shift reaches the preset limit value.
  • In addition to checking and setting blade position, the controller 94 also controls the machine articulation in the instant embodiment. The control of articulation serves three purposes, namely ensuring compliance with certain rules of motion, providing additional side shift capability, and allowing the rear wheels to track the front wheels to the extent such is compatible with the other goals of articulation. Thus, the controller senses the steering angle θ, e.g., via steering input signal 100 at stage 180. At stage 182, the controller 94 adjusts the frame articulation angle α (as sensed via the articulation input signal 104 and controlled via the articulation output 138 to right and left articulation cylinders 64, 66) based on (1) certain rules of travel, e.g., disallowing impact of rear wheels on curb, (2) the amount of remaining blade side shift needed if any and (3) the detected steering angle θ.
  • In an embodiment, these goals are enforced in order. For example, an articulation adjustment needed to avoid having the rear wheels impact the curb will take priority over any adjustments needed to provide additional blade side shift or to cause the front and rear wheels to track. Moreover, if no risk of curb impact is apparent, any adjustment needed to provide additional blade side shift will take priority over adjustments needed to cause the front and rear wheels to track. Finally, if articulation adjustments are not needed to avoid curb impact or to provide side shift, then articulation adjustment to allow the wheels to track may be made.
  • In addition, in one aspect, a warning or indicator may be provided for the operator when articulation is being actively changed by the controller 94. In an embodiment, if the articulation available within the above limits is not sufficient to allow the blade 30 to continue tracking the curve, the controller 94 may additionally adjust the blade circle shift to provide additional range of blade side movement.
  • The manner of linking the detected steering angle θ to a desired articulation angle a for wheel tracking may be executed via any suitable method. For example, the process described in U.S. Patent Application Publication No. 20110035109 controls articulation based on steering angle in a manner such that a rear centerline point will track a front centerline point. It will be appreciated that other types of steering-based articulation control may be used instead depending upon the implementation environment. For example, rather than tracking front wheel steering, articulation may be used to accentuate or dampen steering inputs.
  • Returning to FIG. 7, as the machine 10 proceeds along the marker, the controller 94 determines at stage 184 whether the operator has steered the machine 10 out of range of the marker, and lifts the blade 30 and reverts to manual control at stage 186 if this has occurred. Otherwise, the process 160 loops back to stage 174 to reevaluate and refine blade position as the machine 10 moves forward. Even without movement of the blade 30 itself relative to the machine 10, it will be appreciated that changes in blade position relative to the marker may occur because of machine movement due to steering and articulation and/or because of lateral variations in the position of the marker.
  • In an alternative embodiment, the controller 94 adjusts frame articulation and blade position in conjunction with one another rather than adjusting these variables sequentially, based on marker trends and/or upcoming marker features such as curvature of the marker. For example, if the blade edge is detected to be too far from the curb or other marker, the controller 94 may determine whether the marker curves within an upcoming predetermined distance such as a machine length, 30 feet, or other desired measure. If the marker does curve within the established distance, the controller 94 may wait to receive an anticipated steering change and may then use articulation adjustment in conjunction with blade shift to close the gap between the blade edge and the marker to the appropriate distance.
  • Similarly, the controller 94 may utilize frame articulation and blade shift to balance one another to allow the greatest remaining freedom of adjustment as the machine 10 continues forward. For example, if the current blade shift position is far off center and nearing a travel limit to the left or right, the controller 94 may readjust the blade shift toward the center while adjusting the frame articulation to account for the altered blade edge position relative to the marker.
  • In a specific example, if the blade edge is displaced too far off center toward the marker, the controller 94 may shift the blade 30 back toward center while reducing the articulation, with the result that the gap between the blade edge and the marker remains as desired. However, as noted above, the operator may steer so far from the marker that the full range of blade shift and frame articulation are not sufficient to keep the gap at the appropriate measure. In this case, as in stages 168 and 184 of FIGS. 6 and 7 respectively, the controller 94 may consider the machine 10 to be out of range and may terminate the selected automation process.
  • Returning briefly to FIG. 5, if stage 154 directs the process 150 to jump point C, then fully automatic control has been selected, and the controller 94 executes the process 188 shown in FIG. 8. In an embodiment, fully automatic control entails control of machine blade side shift, front wheel steering and rear frame articulation (herein “articulation”) to maintain a set gap to the curb or other marker. In addition, machine speed may optionally be controlled to remain below a predetermined set point. Alternatively, the process 188 may require a check of machine speed prior to beginning as discussed with respect to other embodiments above.
  • In executing the process 188, the controller 94 initially receives a marker sensor position signal or determines an appropriate direction for the marker sensor and positions the marker sensor automatically at stage 190 as discussed above. At this time, the controller 94 may prompt the operator via a visual display to set blade tip, blade circle angle, and optionally to set an appropriate gap between the blade and the curb or other marker, e.g., via a display driven process as discussed above.
  • The controller 94 then determines the distance from the blade 30 to the detected marker at stage 192 and moves the blade 30 at stage 194 to the extent needed so that the distance from the blade edge to the marker matches the preset blade gap distance if the user has not manually set the gap and to the extent that such movement does not violate a preset range limit
  • As the machine 10 then moves forward, the controller 94 maintains the gap initially set between the blade 30 and the selected curve primarily by adjusting blade side shift via the blade side shift cylinder 53 and/or the center shift cylinder 40 at stage 194. If the blade shift is limited to less than the actual available range of blade side shift as discussed above, then any unmet side shift requirement may be accommodated in the later steps. In this embodiment, a warning indicator may be provided when the side shift reaches the preset limit value.
  • At stage 196, the controller 94 controls the machine steering angle θ and frame articulation angle α to provide any additional side shift to the extent such is compatible with any rules of motion such as disallowing impact of the rear wheels on the curb or other marker. Thus, in stage 196, the controller 94 adjusts the steering angle and articulation angle to move the machine 10 closer to or farther away from the curb in order to assist in maintaining the gap at the desired value while also keeping the blade side shift within an acceptable range, to the extent the adjustment does not violate a rule of motion. The desired distance range between the front and rear tires to the target curve to be graded may be maintained by adjusting the steering angle and the articulation angle.
  • The relationship between the steering angle θ and articulation angle α may be specified in any desired manner, but in an embodiment, steering and articulation angles are set such that a rear centerline point will track a front centerline point as discussed above. If the articulation available within the above limits is not sufficient to allow the blade 30 to continue tracking the curve without violating a restriction as noted above, the controller 94 may additionally adjust the blade circle shift to provide additional range of blade side movement.
  • As the machine 10 proceeds along the marker, the controller 94 adjusts steering angle and frame articulation angle in concert at stage 198 to follow the target curve. If the curve ends as determined at stage 200 (except for momentary termination with an expected resumption, e.g., after a gap) or if the user manually terminates the automatic control process as determined at stage 202, then the process 188 ends. Otherwise, the process 188 continues to execute stage 198 in order to follow the target curve.
  • Although not explicitly shown in FIGS. 6-8, the controller 94 may control the machine speed during any automated mode, e.g., to maintain a constant speed in addition to ensuring that machine speed is less than a predetermined threshold speed. For example, automatic speed control may be useful during operations in environments having frequent grade changes.
  • In an embodiment, the controller 94 exits any automatic blade gap setting mode in the event that the operator either attempts to control an automated or fixed function such as blade depth or shift, or manipulates a manual control, such as steering, to the extent that the machine 10 is placed beyond an automatically correctable range. Similarly, if the operator at any time switches from an automatic mode into manual mode, the controller 94 returns the machine 10 to manual control. In a further embodiment, the controller 94 causes the blade 30 to be lifted when switching out of any automatic mode into manual mode.
  • As noted above with reference to FIG. 9, a user-friendly display may be provided to allow more efficient setting and monitoring of the automated grading tasks discussed herein. In particular, FIG. 9 illustrates a display usable to show the blade-curb gap the operator and to allow the operator to appropriately set the gap. It will be appreciated that the same display can also be used to show the blade tracking the curb in real time as the motor grader progresses forward.
  • Other display features similarly allow enhanced operator control or ease of use in further embodiments. For example, as shown in FIG. 10, and as discussed briefly above, the system may display a map or worksite diagram, referred to herein as a record image 230, showing areas that have, and have not been, graded. The record image 230 may be displayed at a different time, e.g., later, than other images discussed herein or may be displayed simultaneously, e.g., via a split screen.
  • In the illustrated example, the graded portion 232 of the worksite is shown via a distinct shading on the worksite diagram 230. However, the graded portion 232 may alternatively be indicated by another static indicator such as color or intensity of illumination, or by a dynamic indicator such as blinking.
  • The worksite diagram 230 may also be used to delineate areas in which the set blade-curb gap was not maintained (“nonconforming portions”), for example due to slippage or jolting of the machine 10 or due to the operator temporarily taking the machine 10 out of range. In the illustrated embodiment, the area in which the blade-curb gap was not maintained is indicated by box 234. Other ways of indicating the error are possible, including distinguishing the affected area of the worksite diagram 230 by distinct coloring, shading, or other distinctive indicator.
  • In order for the operator or supervisor to navigate on the display, e.g., to enlarge a certain portion of the worksite diagram 230 or pan to a different portion of the worksite diagram 230, display controls 236 are provided in an embodiment. In the illustrated embodiment, the display controls 236 include panning controls 238 as well as “zoom in” control 240 and a “zoom out” control” 242.
  • INDUSTRIAL APPLICABILITY
  • In general terms, the present disclosure sets forth a system and method for control of a motor grader during operations that track a roadway marker such as a curb. In one embodiment, the system and method control one or more aspects of the motor grader operation during grading near a cul-de-sac curb. In a further embodiment, a machine operator may select a mode of operation, with exemplary modes of operation including a manual mode, a blade automation mode, a blade and steering automation mode, and a full auto mode wherein blade shift, machine steering, and machine articulation are automated to track the marker.
  • At any time during automated operation, the operator may change modes or, in an embodiment, simply control the machine out of a current automated mode, in which case the machine reverts to the manual mode. The method and system for motor grader operation described herein maintain a desired gap between the blade and the marker to prevent the motor grader blade from impacting the marker during operation, especially during operations adjacent curved markers such as cul-de-sac curbs.
  • In addition to allowing an operator to maintain a motor grader blade at a fixed distance from a curb or other marker, the distance data gathered in this process can also be used in a historical manner to provide a record of a grading process. For example, the data are used in an embodiment to provide the operator with a map of areas that have been graded with the desired gap, i.e., what areas have been traversed with blade control engaged. This record may be optionally superimposed on a site map to provide an operator or supervisor with a record of work done and a representation of work yet to be done. In a further embodiment, the display includes one or more indicators showing areas that experienced issues to be corrected or noted, such as areas where the gap-to-curb setting was violated.
  • It will be appreciated that the present disclosure provides an effective and efficient mechanism and control system for motor grader control. Not only do the described system and method generally improve operator comfort and reduce operator fatigue, but they also yield a high-quality grading product with less operator training and experience than might otherwise be required.
  • While only certain examples of the described system and method have been set forth, alternatives and modifications will be apparent from the above description to those skilled in the art.

Claims (26)

What is claimed is:
1. A method for controlling a motor grader having a blade for grading an underlying surface, the method comprising:
displaying a blade image on a display screen to an operator of the motor grader, the blade image having a representation of at least a portion of the blade and at least a portion of a curb adjacent the motor grader;
receiving an input from the operator to move the blade such that a gap between the portion of the blade and the portion of the curb conforms to a target distance;
monitoring the gap between the portion of the blade and the portion of the curb as the motor grader moves along the curb and automatically adjusting the location of the blade relative to the curb such that the gap remains at the target distance; and
updating the blade image as the motor grader moves along the curb.
2. The method for controlling a motor grader in accordance with claim 1, wherein the representation of at least a portion of the curb is a cross-sectional image.
4. The method for controlling a motor grader in accordance with claim 1, wherein the blade image is one of a camera image and a computer-generated image.
5. The method for controlling a motor grader in accordance with claim 1, wherein the display screen is a touch screen and wherein receiving an input from the operator to move the blade includes receiving operator input via the touch screen.
6. The method for controlling a motor grader in accordance with claim 5, wherein the displayed portion of the curb contains a plurality of features of the curb, the method further comprising receiving an operator selection of one of the plurality of features of the curb from which to measure the gap.
7. The method for controlling a motor grader in accordance with claim 6, further comprising displaying on the display screen a curve tracking the selected feature of the curb.
8. The method for controlling a motor grader in accordance with claim 7, wherein the selected feature of the curb has a broken portion, and wherein the curve tracking the selected feature of the curb is interpolated across the broken portion.
9. The method for controlling a motor grader in accordance with claim 1, wherein receiving an input from the operator to move the blade includes receiving an input of a distance value in a distance field on the display.
10. The method for controlling a motor grader in accordance with claim 1, further comprising displaying a record image identifying portions of the underlying surface that the motor grader has graded.
11. The method for controlling a motor grader in accordance with claim 10, wherein the record image and blade image are displayed simultaneously on the display screen via a split screen display.
12. The method for controlling a motor grader in accordance with claim 10, wherein the record image further identifies nonconforming portions of the underlying surface that have been graded while the gap between the blade and the curb substantially differed from the target distance.
13. The method for controlling a motor grader in accordance with claim 12, wherein the record image further identifies nonconforming portions of the underlying surface by displaying such portions in a color that differs from a color used to display other portions of the underlying surface.
14. The method for controlling a motor grader in accordance with claim 1, further comprising sounding an audible alarm during grading when the gap between the blade and the curb substantially differs from the target distance.
15. The method for controlling a motor grader in accordance with claim 1, further comprising displaying a visible alert on the display screen during grading when the gap between the blade and the curb substantially differs from the target distance.
16. A controller for providing display-based control of a motor grader having a blade for grading an underlying surface, the controller having computer-executable instructions on a computer-readable medium associated therewith comprising instructions for:
displaying a blade image on a display screen to an operator of the motor grader, the blade image having a representation of at least a portion of the blade and at least a portion of a curb adjacent the motor grader;
receiving an input from the operator to move the blade such that a gap between the portion of the blade and the portion of the curb conforms to a target distance;
monitoring the gap between the portion of the blade and the portion of the curb as the motor grader moves along the curb and adjusting the location of the blade relative to the curb such that the gap continues to conform to the target distance; and
updating the blade image as the motor grader moves along the curb.
17. The controller in accordance with claim 16, wherein the display screen is a touch screen and wherein the instructions for receiving an input from the operator to move the blade include instructions for receiving operator input via the touch screen.
18. The controller in accordance with claim 17, wherein the displayed portion of the curb contains a plurality of features of the curb, the computer-executable instructions further comprising instructions for receiving an operator selection of one of the plurality of features of the curb from which to measure the gap.
19. The controller in accordance with claim 18, the computer-executable instructions further comprising instructions for displaying on the display screen a curve tracking the selected feature of the curb.
20. The controller in accordance with claim 16, the computer-executable instructions further comprising instructions for displaying a record image identifying portions of the underlying surface that the motor grader blade has graded and for identifying nonconforming portions of the graded surface wherein the gap between the blade and the curb substantially differed from the target distance during grading.
21. The controller in accordance with claim 16, the computer-executable instructions further comprising instructions for displaying a visible alert on the display screen during grading when the gap between the blade and the curb substantially differs from the target distance.
22. A system for controlling a motor grader during grading near a curb, the motor grader having a blade for grading an underlying surface, the system comprising:
a display for displaying to an operator of the motor grader an image showing a gap between the blade and the curb and for receiving user input to alter the gap to a target distance; and
a controller configured to adjust a position of the blade during grading of the underlying surface to maintain the gap between the blade and the curb at the target distance.
23. The system for controlling a motor grader in accordance with claim 22, further comprising at least one sensor for detecting the gap between the blade and the curb.
24. The system for controlling a motor grader in accordance with claim 23, wherein the at least one sensor is a camera.
25. The system for controlling a motor grader in accordance with claim 22, wherein the controller is further configured to update the image showing the gap between the blade and the curb during grading of the underlying surface.
26. The system for controlling a motor grader in accordance with claim 22, wherein the controller is further configured to display a record image identifying portions of the underlying surface that have been graded and portions that have not been graded.
27. The system for controlling a motor grader in accordance with claim 26, wherein the controller is further configured to identify, via the record image, any portions of the underlying surface which have been graded improperly.
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