AUTOMATED CONTROL OF DIPPER SWING FOR A SHOVEL

• US 20130245897A1
• Filed: 03/15/2013
• Published: 09/19/2013
• Est. Priority Date: 03/16/2012
• Status: Active Grant

• Current Assignee: Joy Global Surface Mining Inc. (Komatsu Ltd.)
• Original Assignee: Harnischfeger Technologies Inc. (Komatsu Ltd.)
• Inventors: Linstroth, Michael, Colwell, Joseph, Emerson, Mark
• Granted Patent: US 9,206,587 B2
• Time in Patent Office: Days
• US Class Current: 701/50
• CPC Class Codes: E02F 3/30 with a dipper-arm pivoted on a cantilever beam , i.e. boom
• CPC Class Codes: E02F 3/435 for dipper-arms, backhoes or the like
• CPC Class Codes: E02F 9/2025 Particular purposes of control systems not otherwise provided for E02F3/16, E02F3/26, sub-groups of E02F3/43, E02F3/651, sub-groups of E02F3/84, E02F3/907, E02F5/145 take precedence
• CPC Class Codes: E02F 9/2029 Controlling the position of implements in function of its load, e.g. modifying the attitude of implements in accordance to vehicle speed control for hydraulic or pneumatic drives E02F9/2203, E02F9/2221 and E02F9/2253 take precedence
• CPC Class Codes: E02F 9/2041 Automatic repositioning of implements, i.e. memorising determined positions of the implement for dipper-arms or bucket-arms E02F3/434, E02F3/437, E02F3/438, E02F3/439 take precedence
• CPC Class Codes: E02F 9/2058 Electric or electro-mechanical or mechanical control devices of vehicle sub-units for vehicles in general B60W
• CPC Class Codes: E02F 9/2079 Control of mechanical transmission for hydrostatic transmission or hydraulic torque converter E02F9/2253
• CPC Class Codes: E02F 9/24 Safety devices , e.g. for preventing overload E02F9/226 takes precedence
• CPC Class Codes: E02F 9/265 with follow-up actions (e.g. control signals sent to actuate the work tool)

Abstract

Systems and methods for compensating dipper swing control. One method includes, with at least one processor, determining a direction of compensation opposite a current swing direction of the dipper and applying the maximum available swing torque in the direction of compensation when an acceleration of the dipper is greater than a predetermined acceleration value. The method can also include determining a current state of the shovel and performing the above steps when the current state of the shovel is a swing-to-truck state or a return-to-tuck state. When the current state of the shovel is a dig-state, the method can include limiting the maximum available swing torque and allowing, with the at least one processor, swing torque to ramp up to the maximum available swing torque over a predetermined period of time when dipper is retracted to a predetermined crowd position.

Claims

1. A method of compensating swing of a dipper of a shovel, the method comprising:

(a) determining, by at least one processor, a direction of compensation opposite a current swing direction of the dipper; and

(b) applying, by the at least one processor, maximum available swing torque in the direction of compensation opposite the current swing direction of the dipper when acceleration of the dipper is greater than a predetermined acceleration value.

2. The method of claim 1, further comprising determining, by the at least one processor, a current state of the shovel and performing steps (a) through (b) when the current state of the shovel is a swing-to-truck state or a return-to-tuck state.

3. The method of claim 1, further comprising, when the current state of the shovel is in a dig state:

(c) limiting the maximum available swing torque; and

(d) allowing swing torque to ramp up to the limited maximum available swing torque over a predetermined period of time when dipper is retracted to a predetermined crowd position.

4. The method of claim 3, wherein limiting the maximum available swing torque includes limiting the maximum available swing torque between approximately 30% and approximately 80% of the maximum available swing torque.

5. The method of claim 3, wherein allowing swing torque to ramp up when the dipper is retracted to a predetermined crowd position includes allowing swing torque to ramp up when the dipper is retracted a predetermined percentage from a maximum crowd position.

6. The method of claim 5, wherein allowing swing torque to ramp up when the dipper is retracted a predetermined percentage from a maximum crowd position includes allowing swing torque to ramp up when the dipper is retracted between approximately 5% and approximately 40% from the maximum crowd position.

7. The method of claim 3, wherein allowing swing torque to ramp up over the predetermined period of time includes allowing the swing torque to ramp up over approximately 100 milliseconds to approximately 2 seconds.

8. The method of claim 1, further comprising increasing the maximum available swing torque before applying the maximum available swing torque in the direction of compensation.

9. The method of claim 8, wherein increasing the maximum available swing torque includes increasing the maximum available swing torque up to approximately 200%.

10. The method of claim 1, further comprising stopping applying the maximum available swing torque in the direction of compensation opposite the swing direction of the dipper when a swing speed of the dipper drops to or below a predetermined speed value.

11. The method of claim 10, wherein stopping applying the maximum available swing torque when the swing speed of the dipper drops to or below a predetermined speed value includes stopping applying the maximum available swing torque when the swing speed of the dipper drops to or below between approximately 0 rpm and approximately 300 rpm.

12. The method of claim 10, wherein stopping applying the maximum available swing torque when the swing speed of the dipper drops to or below a predetermined speed value includes stopping applying the maximum available swing torque when the swing speed of the dipper drops by a predetermined percentage.

13. The method of claim 1, further comprising stopping applying the maximum available swing torque in the direction of compensation opposite the swing direction of the dipper when a timer value reaches a predetermined setpoint.

14. The method of claim 1, wherein applying the maximum available swing torque includes calculating a deceleration speed based on a difference between the acceleration of the dipper and the predetermined acceleration value.

15. The method of claim 1, further comprising determining the predetermined acceleration value based on a full state of the dipper.

16. The method of claim 1, further comprising determining the predetermined acceleration value based on an empty state of the dipper.

17. The method of claim 1, further comprising determining the predetermined acceleration value based on a current dipper load.

18. The method of claim 1, further comprising determining the predetermined acceleration value based on a current dipper position.

19. The method of claim 1, wherein applying the maximum available swing torque includes applying the maximum available swing torque when acceleration of the dipper is greater than a predetermined acceleration value and a swing speed of the dipper reaches a predetermined threshold.

20. The method of claim 1, wherein applying the maximum available swing torque when a swing speed of the dipper reaches a predetermined threshold includes applying the maximum available swing torque when the swing speed of the dipper reaches or exceeds approximately 5% to approximately 40% of a maximum speed.

21. The method of claim 1, further comprising setting swing motoring torque to a predetermined limit.

22. The method of claim 1, wherein setting swing motoring torque to a predetermined limit includes setting swing motoring torque based on an angle of the shovel received from at least one inclinometer.

23. A system for compensating swing of a dipper of a shovel, the system comprising:

a controller including at least one processor, the at least one processor configured to

(a) limit maximum available swing torque,

(b) determine a crowd position of the dipper, and

(c) restrict swing torque ramp up to the limited maximum available swing torque over a predetermined period of time after the dipper reaches a predetermined crowd position.

24. The system of claim 23, wherein the at least one processor is configured to limit the maximum available swing torque to approximately 30% to approximately 80% of the maximum available swing torque.

25. The system of claim 23, wherein the predetermined crowd position includes a predetermined percentage from a maximum crowd position.

26. The system of claim 25, wherein the predetermined percentage from the maximum crowd position is approximately 5% to approximately 30% from the maximum crowd position.

27. The system of claim 23, wherein the predetermined period of time is between approximately 100 milliseconds and 2 seconds.

28. The system of claim 23, wherein the at least one processor is configured to perform steps (a) through (c) when the shovel is in a dig state.

29. The system of claim 23, wherein the at least one processor is further configured to:

(d) determine a direction of compensation opposite a current swing direction of the dipper; and

(e) apply the maximum available swing torque in the direction of compensation opposite the current swing direction of the dipper when an acceleration of the dipper is greater than a predetermined acceleration value.

30. The system of claim 29, wherein the at least one processor is configured to perform steps (d) through (e) when the shovel is in a swing-to-dump state or a return-to-tuck state.

31. The system of claim 29, wherein the at least one processor is further configured to increase the maximum available swing torque by a predetermined percentage before applying the maximum available in the direction of compensation.

32. The system of claim 31, wherein predetermined percentage is up to 200%.

33. The system of claim 29, wherein the at least one processor is further configured to stop applying the maximum available swing torque in the direction of compensation opposite the swing direction of the dipper when a swing speed of the dipper drops to or below a predetermined speed value.

34. The system of claim 33, wherein the predetermined speed value is between approximately 0 rpm and approximately 100 rpm.

35. The system of claim 29, wherein the predetermined acceleration value is based on a full state of the dipper.

36. The system of claim 29, wherein the predetermined acceleration value is based on an empty state of the dipper.

37. The system of claim 29, wherein the predetermined acceleration value is based on a current dipper load.

38. The system of claim 29, wherein the predetermined acceleration value is based on a current dipper position.

39. The system of claim 29, wherein the at least one processor is further configured to apply the maximum available swing torque in the direction of compensation opposite the current swing direction of the dipper when an acceleration of the dipper is greater than a predetermined acceleration value and a swing speed of the dipper reaches a predetermined threshold.

40. The system of claim 39, wherein the predetermined threshold is approximately 5% to approximately 40% of a maximum speed.