Performance-based haulage management system

• US 8,099,217 B2
• Filed: 08/31/2007
• Issued: 01/17/2012
• Est. Priority Date: 08/31/2007
• Status: Expired due to Fees

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Greiner, Jonny Ray, Liu, Yang, Vyas, Bhavin Jagdishbhai
• Primary Examiner(s): Trammell, James
• Assistant Examiner(s): Shafi, Muhammad
• Application Number:
  US11/897,736
• Publication Number:
  US 20090063031A1
• Time in Patent Office: 1,600 Days
• Field of Search: 701/117, 701/50, 701 80- 97, 701/110, 701/114, 705/7, 235/376, 37205-223, 372/33, 372/36, 372/40, 372/42, 372/44, 37246-252, 372/64, 372/66, 372/71, 373/05, 56/101, 56/102.R, 56 103- 104, 56 102 A- 102 H, 56/102.J, 56 105- 176
• US Class Current: 701/50
• CPC Class Codes: G06Q 10/08 Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
• CPC Class Codes: G06Q 50/02 Agriculture; Fishing; Forestry; Mining

Abstract

A method for managing haul routes in work environments comprises collecting performance data associated with a machine operating in a work environment. The method also includes determining a drive axle torque of the machine and estimating a total effective grade associated with the machine based on the drive axle torque. The estimated total effective grade is compared with a threshold level and, if the estimated total effective grade exceeds the threshold level, a design performance of the machine may be simulated based on the calculated total effective grade. Design performance data is compared with the collected performance data, and a payload limit of the machine is adjusted if the design performance is inconsistent with collected performance data.

Claims

1. A computer-implemented method for managing haul routes in work environments, comprising:

collecting, at a processor associated with a computer, performance data associated with a machine during a haul route run in a work environment;

monitoring, by the processor, a route completion time associated with the machine;

comparing, by the processor, the route completion time with a threshold completion time;

selecting, by the processor, a first payload level for the machine if the route completion time exceeds the threshold completion time;

simulating, by the processor, operation of the machine based on the first payload level to generate a simulated route completion time of the machine; and

establishing, by the processor, a payload limit of the machine as the first payload level if the simulated route completion time does not exceed the threshold completion time.

2. The computer-implemented method of claim 1, further including:

selecting, if the simulated route completion time exceeds the threshold completion time, a second payload level for the machine;

simulating operation of the machine based on the second payload level to generate a second simulated route completion time of the machine; and

establishing the payload limit for the machine as the second payload level if the second simulated route completion time does not exceed the threshold completion time.

3. The computer-implemented method of claim 1, further including:

generating a payload notification indicative of the payload limit for the machine; and

providing the payload notification to a payload subscriber.

4. The computer-implemented method of claim 1, further including:

analyzing, if the route completion time exceeds the threshold completion time, the collected performance data to diagnose a potential cause of inconsistency between the route completion time and the threshold completion time; and

generating a report that summarizes the potential cause of the inconsistency and provides recommendations for resolving the potential cause of the inconsistency.

5. The computer-implemented method of claim 4, wherein analyzing the collected data includes:

estimating an actual remaining lifespan associated with one or more components of the machine based on a current payload level; and

generating a simulated remaining lifespan associated with one or more of the components of the machine based on the established payload limit;

wherein the report further summarizes a difference between the estimated remaining lifespan and the simulated remaining lifespan.

6. The computer-implemented method of claim 1, wherein simulating operation of the machine includes:

generating a model of the machine based on the collected performance data; and

simulating operation of the machine using the generated model.

7. A computer-implemented method for managing haul routes in work environments, comprising:

collecting, at a processor associated with a computer, performance data associated with a machine operating in a work environment;

determining, by the processor, a drive axle torque of the machine and calculating a total effective grade associated with the machine based on the drive axle torque;

comparing, by the processor, calculated total effective grade with a threshold level;

simulating, by the processor, a design performance of the machine based on the calculated total effective grade if the calculated total effective grade exceeds the threshold level;

comparing, by the processor, design performance data with the collected performance data; and

adjusting, by the processor, a payload limit of the machine if the design performance is inconsistent with collected performance data.

8. The computer-implemented method of claim 7, wherein determining the drive axle torque includes monitoring the drive axle torque with a torque sensor.

9. The computer-implemented method of claim 7, wherein determining the drive axle torque includes estimating the drive axle torque based on the collected performance data.

10. The computer-implemented method of claim 7, wherein the threshold level corresponds to a total effective grade associated with one or more other machines operating in the work environment.

11. The computer-implemented method of claim 7, wherein the performance data includes speed of the machine.

12. The computer-implemented method of claim 7, wherein adjusting the payload limit of the machine includes:

selecting a first payload level for the machine;

simulating a speed of the machine based on the first payload level; and

determining whether the simulated speed is within a target speed threshold;

establishing, if the simulated speed is within a target speed threshold, the payload limit for the machine as the first payload level; and

selecting, if the simulated speed is not within a target speed threshold, a second payload level for the machine and simulating the speed of the machine based on the second payload level.

13. The computer-implemented method of claim 12, further including:

generating a payload notification indicative of the payload limit for the machine; and

providing the payload notification to a payload subscriber.

14. The computer-implemented method of claim 13, wherein the payload notification includes a command signal for limiting an amount of material loaded into the machine by an automated loading device.

15. The computer-implemented method of claim 7, further including:

analyzing, if the estimated total effective grade exceeds the threshold level, the collected performance data to determine a potential cause of inconsistency between the collected performance data and the design performance data; and

generating a report that summarizes the potential cause of the inconsistency and provides recommendations for resolving the potential cause of the inconsistency.

16. The computer-implemented method of claim 15, wherein analyzing the collected data includes:

estimating an actual remaining lifespan associated with one or more components of the machine based on a current payload level; and

generating a simulated remaining lifespan associated with one or more of the components of the machine based on the established payload limit;

wherein the report further summarizes a difference between the estimated remaining lifespan and the simulated remaining lifespan.