CONTROLLING CROWD RUNAWAY OF AN INDUSTRIAL MACHINE

• US 20150308073A1
• Filed: 04/24/2015
• Published: 10/29/2015
• Est. Priority Date: 04/25/2014
• Status: Active Grant

• Current Assignee: Joy Global Surface Mining Inc. (Komatsu Ltd.)
• Original Assignee: Harnischfeger Technologies Inc. (Komatsu Ltd.)
• Inventors: Voelz, Nicholas R., Linstroth, Michael
• Granted Patent: US 9,809,949 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: E02F 3/304 with the dipper-arm slidably mounted on the boom E02F3/305 takes precedence
• CPC Class Codes: E02F 3/308 working outwardly
• CPC Class Codes: E02F 3/435 for dipper-arms, backhoes or the like
• CPC Class Codes: E02F 3/46 with reciprocating digging or scraping elements moved by cables or hoisting ropes ; Drives or control devices therefor E02F3/205, E02F3/905 take precedence
• CPC Class Codes: E02F 9/2033 Limiting the movement of frames or implements, e.g. to avoid collision between implements and the cabin sub-groups of E02F3/431 of E02F3/435 take precedence; for turntables E02F9/123
• CPC Class Codes: E02F 9/265 with follow-up actions (e.g. control signals sent to actuate the work tool)

Abstract

A system for controlling the operation of an industrial machine during crowd runaway conditions. The system includes a controller that monitors and compares an actual crowd system state (e.g., an actual dipper position) with a requested crowd system state (e.g., a requested dipper position from the operator). If the controller determines that the crowd system is behaving contrary to requested crowd system behavior, the controller adjusts a crowd parameter, such as a crowd motor torque, to resolve the runaway condition.

Claims

1. An industrial machine comprising:

a dipper;

a sensor operable to generate a first signal related to an actual crowd system state;

a user interface operable to generate a second signal related to a requested crowd system state based on an operator input;

a crowd motor having at least one operating parameter; and

a controller configured to

receive the first signal related to the actual crowd system state,

receive the second signal related to the requested crowd system state,

determine a difference between the requested crowd system state and the actual crowd system state,

compare the difference between the requested crowd system state and the actual crowd system state to a threshold, and

set the at least one operating parameter of the crowd motor to a value when the difference is greater than or equal to the threshold, the value being greater than a normal operating value for the operating parameter.

2. The industrial machine of claim 1, wherein the requested crowd system state includes at least one of a requested crowd motor direction, a requested crowd motor current, or a requested crowd motor speed.

3. The industrial machine of claim 1, wherein the actual crowd system state and includes at least one of an actual crowd motor direction, an actual crowd motor current, or an actual crowd motor speed.

4. The industrial machine of claim 1, wherein the at least one operating parameter is a crowd retract torque.

5. The industrial machine of claim 4, wherein, when the difference is greater than or equal to the threshold, the value for the crowd retract torque is calculated based on a ratio of the actual crowd system state and the requested crowd system state.

6. The industrial machine of claim 4, wherein, when the difference is greater than or equal to the threshold, the value for the crowd retract torque is calculated based on a function of the difference.

7. The industrial machine of claim 6, wherein the controller is configured to apply brakes to the crowd motor.

8. A method of controlling a motor of an industrial machine, the method comprising:

receiving, at a processor, a first signal related to an actual crowd system state;

receiving, at the processor, a second signal related to a requested crowd system state;

determining, with the processor, a difference between the requested crowd system state and the actual crowd system state;

comparing, with the processor, the difference between the requested crowd system state and the actual crowd system state to a threshold; and

setting, with the processor, the at least one operating parameter of the motor to a value when the difference is greater than or equal to the threshold, the value being greater than a normal operating value for the operating parameter.

9. The method of claim 8, wherein the first signal is received from a user interface based on an operator input.

10. The method of claim 8, wherein the requested crowd system includes at least one of a requested crowd motor direction, a requested crowd motor current, or a requested crowd motor speed.

11. The method of claim 8, wherein the actual crowd system state includes at least one of an actual crowd motor direction, an actual crowd motor current, or an actual crowd motor speed.

12. The method of claim 8, wherein the motor is a crowd motor and the at least one operating parameter is a crowd retract torque.

13. The method of claim 12, further comprising calculating the value for the crowd retract torque based on a ratio of the actual crowd system state and the requested crowd system state when the difference is greater than or equal to the threshold.

14. The method of claim 12, further comprising calculating the value for the crowd retract torque based on a function of the difference when the difference is greater than or equal to the threshold.

15. The method of claim 14, further comprising applying, with the processor, brakes to the crowd motor.

16. An industrial machine comprising:

a dipper;

a sensor operable to generate a first signal related to an actual crowd system state;

a user interface operable to generate a second signal related to a requested crowd system state based on an operator input;

a crowd motor having at least one operating parameter; and

a controller configured to

receive the first signal related to the actual crowd system state,

receive the second signal related to the requested crowd system state,

determine a requested dipper movement direction based on the second signal, determine an actual dipper movement direction based on the first signal,

determine whether the requested dipper movement direction and the actual dipper movement direction are the same, and

set the at least one operating parameter of the crowd motor to a value when the requested dipper movement direction is not the same as the actual dipper movement direction, the value being greater than a normal operating value for the operating parameter.

17. The industrial machine of claim 16, wherein the requested crowd system state includes at least one of a requested crowd motor direction, a requested crowd motor current, or a requested crowd motor speed.

18. The industrial machine of claim 16, wherein the actual crowd system state includes at least one of an actual crowd motor direction, an actual crowd motor current, or an actual crowd motor speed.

19. The industrial machine of claim 16, wherein the at least one operating parameter is a crowd retract torque.

20. The industrial machine of claim 19, wherein the value of the crowd retract torque is greater than 100% of a normal operating torque.

21. The industrial machine of claim 20, wherein the controller is configured to apply brakes to the crowd motor.

22. The industrial machine of claim 19, wherein the value of the crowd retract torque is a predetermined fixed value.

23. A method of controlling a motor of an industrial machine, the method comprising:

receiving, at a processor, a first signal related to an actual crowd system state;

receiving, at the processor, a second signal related to a requested crowd system state;

determining, with the processor, a requested dipper movement direction based on the second signal;

determining, with the processor, an actual dipper movement direction based on the first signal;

determining, with the processor, whether the requested dipper movement direction and the actual dipper movement direction are the same; and

setting, with the processor, the at least one operating parameter of the motor to a value when the requested dipper movement direction is not the same as the actual dipper movement direction, the value being greater than a normal operating value for the operating parameter.

24. The method of claim 23, wherein the second signal is received from a user interface based on an operator input.

25. The method of claim 23, wherein the requested crowd system includes at least one of a requested crowd motor direction, a requested crowd motor current, or a requested crowd motor speed.

26. The method of claim 23, wherein the actual crowd system state includes at least one of an actual crowd motor direction, an actual crowd motor current, or an actual crowd motor speed.

27. The method of claim 23, wherein the motor is a crowd motor and the at least one operating parameter is a crowd retract torque.

28. The method of claim 27, wherein the value of the crowd retract torque is greater than 100% of a normal operating torque.

29. The method of claim 28, further comprising applying, with the processor, brakes to the crowd motor.

30. The method of claim 27, wherein the value of the crowd retract torque is a predetermined fixed value.