Performance-based haulage management system

• US 8,437,924 B2
• Filed: 12/12/2011
• Issued: 05/07/2013
• Est. Priority Date: 08/31/2007
• Status: Active Grant

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Liu, Yang, Vyas, Bhavin, Greiner, Johny
• Primary Examiner(s): Trammell, James
• Assistant Examiner(s): Shafi, Muhammad
• Application Number:
  US13/316,894
• Publication Number:
  US 20120083968A1
• Time in Patent Office: 512 Days
• Field of Search: 701/50, 701 80- 97, 701/110, 701/114, 701/470, 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, 235/376
• 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 haul route management system, comprising:

a condition monitoring system in data communication with a machine operating in a work environment and configured to collect performance data associated with the machine;

a torque estimator communicatively coupled to the condition monitoring system and configured to determine a drive axle torque of the machine and estimate a total effective grade associated with the machine based on the drive axle torque;

a performance simulator communicatively coupled to the torque estimator and the condition monitoring system, wherein the performance simulator is configured to;

compare the estimated total effective grade with a threshold level;

simulate, if the estimated total effective grade exceeds the threshold level, a design performance of the machine based on the estimated total effective grade;

compare design performance data with the collected performance data;

perform a payload analysis of the machine if the collected performance data is inconsistent with the design performance data; and

establish a payload limit of the machine based on the payload analysis.

2. The system of claim 1, wherein the condition monitoring system is wirelessly coupled to an on-board data collector of the machine and configured to receive performance data from the on-board data collector during operations of the machine.

3. The system of claim 1, wherein the performance simulator is further configured to:

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

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

4. The system of claim 3, wherein the performance simulator is further configured to:

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

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

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

5. The system of claim 1, wherein performing the payload analysis includes:

selecting a first payload level for the machine;

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

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

wherein establishing the payload limit for the machine includes establishing, if the simulated speed is within a target speed threshold, the payload limit for the machine as the first payload level.

6. The system of claim 5, further including:

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

providing the payload notification to a payload subscriber.

7. The system of claim 1, wherein the performance simulator includes the torque estimator.

8. The system of claim 1, wherein the performance data includes at least one of a position, a machine speed, a machine acceleration, an engine load factor, a machine payload, a fluid pressure or temperature, a tire pressure, and a gear position.