SYSTEM AND METHOD FOR UNDERWATER PAYLOAD ESTIMATION IN DRAGLINE BUCKET
20260117486 ยท 2026-04-30
Assignee
Inventors
- Saravanan Varadharaj Anthipagulu (Tiruvallur, IN)
- Gopalakrishnan Kanniappan (Tiruvallur, IN)
- Michael Robert Stolz (Franklin, WI, US)
- Koushik KABIRAJ (Chennai, IN)
- Vijeendra Nadgir (Ballari, IN)
- Pradheep Arumugam Shanmugasundaram (Coimbatore, IN)
- Jaiveena R. (Salem, IN)
Cpc classification
E21C50/00
FIXED CONSTRUCTIONS
International classification
E02F5/14
FIXED CONSTRUCTIONS
E02F5/00
FIXED CONSTRUCTIONS
Abstract
A system for underwater payload estimation in a dragline bucket of a dragline machine includes a sensing module disposed on the dragline bucket. The sensing module is configured to generate a plurality of signals indicative of a distance value between the sensing module and payload in the dragline bucket. The system includes a controller including at least one memory and at least one processor communicably coupled with the at least one memory and the sensing module. The at least one processor is configured to receive, from the sensing module, the plurality of signals indicative of the distance value between the sensing module and the payload in the dragline bucket, when the dragline bucket is underwater. The at least one processor is configured to estimate a volume of the payload in the dragline bucket when the dragline bucket is underwater, based on the plurality of signals received.
Claims
1. A system for underwater payload estimation in a dragline bucket of a dragline machine, the system comprising: a sensing module disposed on the dragline bucket, wherein the sensing module is configured to generate a plurality of signals indicative of a distance value between the sensing module and payload in the dragline bucket; and a controller including at least one memory and at least one processor communicably coupled with the at least one memory and the sensing module, wherein the at least one processor is configured to: receive, from the sensing module, the plurality of signals indicative of the distance value between the sensing module and the payload in the dragline bucket, when the dragline bucket is underwater; estimate a volume of the payload in the dragline bucket when the dragline bucket is underwater, based on the plurality of signals received from the sensing module; and generate an output signal indicative of the estimated volume of the payload in the dragline bucket.
2. The system of claim 1 further comprising an output module communicably coupled with the at least one processor, wherein the output module is configured to receive the output signal from the at least one processor and generate a notification to indicate the estimated volume of the payload in the dragline bucket.
3. The system of claim 2, wherein the output module is a display device, and wherein the notification includes a two-dimensional image indicative of the estimated volume of the payload in the dragline bucket, a three-dimensional image indicative of the estimated volume of the payload in the dragline bucket, an absolute value of the estimated volume of the payload in the dragline bucket, and/or a percentage value of the estimated volume of the payload in the dragline bucket.
4. The system of claim 2, wherein the at least one processor is further configured to: compare the estimated volume of the payload in the dragline bucket with a predetermined threshold volume of payload; generate the output signal if the estimated volume of the payload in the dragline bucket is lesser than the predetermined threshold volume of payload; and transmit, to the output module, the output signal.
5. The system of claim 4, wherein the output module is configured to receive the output signal from the at least one processor and generate an alert to indicate that the estimated volume of the payload in the dragline bucket is lesser than the predetermined threshold volume of payload.
6. The system of claim 1, wherein the sensing module includes a sonar sensor, an acoustic sensor, a camera, a light detection and raging (LIDAR) sensor, and/or a radio detection and ranging (RADAR) sensor.
7. The system of claim 1, wherein, the sensing module is connected with the controller via a wired connection or a wireless connection, and wherein, when the sensing module is connected with the controller via the wireless connection, the system further includes a transmitter disposed on the dragline bucket, and a receiver disposed on the dragline machine and external to the dragline bucket.
8. The system of claim 1, wherein the sensing module is disposed on an arch of the dragline bucket.
9. A dragline machine comprising: a frame; a dragline bucket; and a system for underwater payload estimation in the dragline bucket, the system comprising: a sensing module disposed on the dragline bucket, wherein the sensing module is configured to generate a plurality of signals indicative of a distance value between the sensing module and payload in the dragline bucket; and a controller including at least one memory and at least one processor communicably coupled with the at least one memory and the sensing module, wherein the at least one processor is configured to: receive, from the sensing module, the plurality of signals indicative of the distance value between the sensing module and the payload in the dragline bucket, when the dragline bucket is underwater; estimate a volume of the payload in the dragline bucket when the dragline bucket is underwater, based on the plurality of signals received from the sensing module; and generate an output signal indicative of the estimated volume of the payload in the dragline bucket.
10. The dragline machine of claim 9, wherein the system further includes an output module communicably coupled with the at least one processor, and wherein the output module is configured to receive the output signal from the at least one processor and generate a notification to indicate the estimated volume of the payload in the dragline bucket.
11. The dragline machine of claim 10, wherein the output module is a display device, and wherein the notification includes a two-dimensional image indicative of the estimated volume of the payload in the dragline bucket, a three-dimensional image indicative of the estimated volume of the payload in the dragline bucket, an absolute value of the estimated volume of the payload in the dragline bucket, and/or a percentage value of the estimated volume of the payload in the dragline bucket.
12. The dragline machine of claim 10, wherein the at least one processor is further configured to: compare the estimated volume of the payload in the dragline bucket with a predetermined threshold volume of payload; generate the output signal if the estimated volume of the payload in the dragline bucket is lesser than the predetermined threshold volume of payload; and transmit, to the output module, the output signal.
13. The dragline machine of claim 12, wherein the output module is configured to receive the output signal from the at least one processor and generate an alert to indicate that the estimated volume of the payload in the dragline bucket is lesser than the predetermined threshold volume of payload.
14. The dragline machine of claim 9, wherein the sensing module includes a sonar sensor, an acoustic sensor, a camera, a light detection and raging (LIDAR) sensor, and/or a radio detection and ranging (RADAR) sensor.
15. The dragline machine of claim 9, wherein, the sensing module is connected with the controller via a wired connection or a wireless connection, and wherein, when the sensing module is connected with the controller via the wireless connection, the system further includes a transmitter disposed on the dragline bucket, and a receiver disposed on the dragline machine and external to the dragline bucket.
16. The dragline machine of claim 9, wherein the sensing module is disposed on an arch of the dragline bucket.
17. A method of underwater payload estimation in a dragline bucket of a dragline machine, the method comprising: disposing a sensing module on the dragline bucket; generating, by the sensing module, a plurality of signals indicative of a distance value between the sensing module and payload in the dragline bucket; receiving, by at least one processor of a controller, the plurality of signals indicative of the distance value between the sensing module and the payload in the dragline bucket from the sensing module, when the dragline bucket is underwater, wherein the at least one processor is communicably coupled with at least one memory of the controller and the sensing module; estimating, by the at least one processor, a volume of the payload in the dragline bucket when the dragline bucket is underwater, based on the plurality of signals received from the sensing module; and generating, by the at least one processor, an output signal indicative of the estimated volume of the payload in the dragline bucket.
18. The method of claim 17 further comprising: receiving, by an output module, the output signal from the at least one processor, wherein the output module is communicably coupled with the at least one processor; and generating, by the output module, a notification to indicate the estimated volume of the payload in the dragline bucket.
19. The method of claim 18, wherein the output module is a display device, and wherein the step of generating, by the output module, the notification to indicate the estimated volume of the payload in the dragline bucket further includes generating a two-dimensional image indicative of the estimated volume of the payload in the dragline bucket, a three-dimensional image indicative of the estimated volume of the payload in the dragline bucket, an absolute value of the estimated volume of the payload in the dragline bucket, and/or a percentage value of the estimated volume of the payload in the dragline bucket.
20. The method of claim 18 further comprising: comparing, by the at least one processor, the estimated volume of the payload in the dragline bucket with a predetermined threshold volume of payload; generating, by the at least one processor, the output signal if the estimated volume of the payload in the dragline bucket is lesser than the predetermined threshold volume of payload; receiving, by the output module, the output signal from the at least one processor; and generate, by the output module, an alert to indicate that the estimated volume of the payload in the dragline bucket is lesser than the predetermined threshold volume of payload.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0018] Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
[0019]
[0020] The dragline machine 100 includes a frame 102. Further, the dragline machine 100 also includes an enclosure 104. The dragline machine 100 further includes a power source (not shown). In addition to other components, the enclosure 104 may house the power source. The power source may supply power to various components of the dragline machine 100 for operating one or more components of the dragline machine 100 and to facilitate a movement of the dragline machine 100. In one example, the power source may include an engine, such as, a diesel engine, a gasoline engine, a gaseous fuel-powered engine, or any other type of engine known in the art. In other examples, the power source may include a battery system, a fuel cell, and the like.
[0021] Although not shown herein, the dragline machine 100 may include ground engaging members, such as, wheels, tracks, or a walking mechanism for mobility. The dragline machine 100 includes a boom 106. The boom 106 is controlled by a suspension system 108 connected to a mast 110 and a gantry frame 112. The dragline machine 100 further includes a rigging assembly 114 coupled to one or more hoist ropes 116.
[0022] The dragline machine 100 includes a bucket assembly 200 coupled to the rigging assembly 114. The dragline machine 100 also includes a dragline bucket 202. Further, the rigging assembly 114 includes a drag socket 118 and one or more drag ropes 120. The hoist ropes 116 pass over a boom point sheave 122 of the boom 106 and suspends the dragline bucket 202 therefrom. Further, the dragline bucket 202 is coupled to the drag ropes 120 by the drag socket 118.
[0023] The rigging assembly 114 includes a hoist socket 124 and a spreader bar (not shown). The rigging assembly 114 further includes a number of hoist chains 130. The spreader bar along with the hoist chains 130 suspends the dragline bucket 202. Further, the dragline bucket 202 can be moved by the drag chains 136 and a dump rope 138 that is connected to the dragline bucket 202 by a dump sheave 140.
[0024] Referring now to
[0025] The dragline bucket 202 may also include a number of teeth (not shown) that may engage with work surfaces. Further, the dragline bucket 202 also includes a number of holes 214 defined on the side wall 206 to filter out water during the excavation, to maintain a higher digging efficiency of the dragline bucket 202. It should be noted that the dragline bucket 202 may include any conventional design known in the art.
[0026] Referring now to
[0027] Referring again to
[0028] Referring to
[0029] Referring to
[0030] Further, a power source (not shown) may provide a power supply to the sensing module 302 for operation thereof. In some examples, the support structure 303 may house the power source. The power source may be connected to the sensing module 302 by a wired connection or a wireless connection. In an example, the power source may be an inbuilt power source, such as, a battery.
[0031] Referring again to
[0032] The one or more processors 314 estimate a volume of the payload in the dragline bucket 202 when the dragline bucket 202 is underwater, based on the number of signals 304 received from the sensing module 302. The one or more processors 314 generate an output signal 316 indicative of the estimated volume of the payload in the dragline bucket 202.
[0033] In some examples, the sensing module 302 includes a sonar sensor, an acoustic sensor, a camera, a light detection and raging (LIDAR) sensor, and/or a radio detection and ranging (RADAR) sensor. The camera may include, for example, a thermal camera, a motion camera, a still camera, and the like. It should be noted that the sensing module 302 may include any other type of sensor to determine the amount of payload in the dragline bucket 202. Further, the system 300 may include any number of sensing modules 302. The sensing module 302 measures time taken between emission and reception of an emitted pulse/wave/signal. Accordingly, the distance value between the sensing module 302 and the payload in the dragline bucket 202 may be determined.
[0034] Referring now to
[0035] The housing 336 has a first portion 338 and a second portion 340. When the sensing module 302 is coupled with the support structure 303 (see
[0036] Referring back to
[0037] In some examples, the output module 330 is a display device 332. The display device 332 may include any Input/Output device having a display screen to provide various information to operators. The display device 332 may be disposed within an operator cabin 142 (shown in
[0038] As shown in
[0039] Referring to
[0040] The output module 330 receives the output signal 316 from the one or more processors 314 and generates an alert to indicate that the estimated volume of the payload in the dragline bucket 202 is lesser than the predetermined threshold volume of payload P1. In some examples, the alert may be an audible alert or a visual alert. The alert may notify operators that the dragline bucket 202 can be further loaded with payload to realize the full capability of the dragline bucket 202.
[0041] In some examples, the output module 330 may include an audio device 334. The audio device 334 may include a speaker, for example. The audio device 334 may be integral with the display device 332, or the audio device 334 may be separated from the display device 332. In an example, the audio device 334 may generate an audio message to inform the operators that the estimated volume of the payload in the dragline bucket 202 is lesser than the predetermined threshold volume of payload P1. Alternatively, the audio device 334 may generate a buzzer or any other type of audible sound to inform the operators that the estimated volume of the payload in the dragline bucket 202 is lesser than the predetermined threshold volume of payload P1. In some cases, the audio device 334 may also generate an audible alert to notify the operators regarding the amount of payload in the dragline bucket 202.
[0042] In another example, the display device 332 may receive the output signal 316 and generate the visual alert to inform the operators that the estimated volume of the payload in the dragline bucket 202 is lesser than the predetermined threshold volume of payload P1. The visual alert may include, for example, a text message, an image displayed on the display device 332, and the like.
[0043] It should be noted that the present disclosure is not limited by a type of alert/notification provided by the output module 330.
[0044] Referring now to
[0045] It is to be understood that individual features shown or described for one embodiment may be combined with individual features shown or described for another embodiment. The above-described implementation does not in any way limit the scope of the present disclosure. Therefore, it is to be understood although some features are shown or described to illustrate the use of the present disclosure in the context of functional segments, such features may be omitted from the scope of the present disclosure without departing from the spirit of the present disclosure as defined in the appended claims.
Industrial Applicability
[0046] The present disclosure relates to the system 300 for underwater payload estimation in the dragline bucket 202 of the dragline machine 100 and a method 400 of underwater payload estimation in the dragline bucket 202 of the dragline machine 100. The system 300 may be retrofitted on existing dragline machines. The system 300 described herein may improve a productivity of the dragline machine 100 by providing an indication of the volume of the payload in the dragline bucket 202 while the dragline bucket 202 is underwater. Accordingly, operators may take an action to further fill the dragline bucket 202 to increase the volume of the payload being carried by the dragline bucket 202.
[0047] The system 300 includes the sensing module 302 disposed on the dragline bucket 202. The sensing module 302 determines the volume of the payload in the dragline bucket 202 underwater by calculating the distance value between the sensing module 302 and the payload in the dragline bucket 202. The distance value between the sensing module 302 and the payload in the dragline bucket 202 may be calculated by the time taken between the emission and the reception of the emitted pulse/wave by the sensing module 302. Thus, the system 300 helps in determining a fill factor of the dragline bucket 202 in real time, thereby reducing the cycle time of each digging operation and improving an efficiency of the dragline machine 100.
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[0049] At step 404, the sensing module 302 generates the number of signals 304 indicative of the distance value between the sensing module 302 and the payload in the dragline bucket 202.
[0050] At step 406, the one or more processors 314 of the controller 310 receive the number of signals 304 indicative of the distance value between the sensing module 302 and the payload in the dragline bucket 202 from the sensing module 302.
[0051] At step 408, the one or more processors 314 estimate the volume of the payload in the dragline bucket 202, based on the number of signals 304 received from the sensing module 302, when the dragline bucket 202 is underwater.
[0052] At step 410, the one or more processors 314 generate the output signal 316 indicative of the estimated volume of the payload in the dragline bucket 202.
[0053] The method 400 further includes a step (not shown) at which the output module 330 receives the output signal 316 from the one or more processors 314. The method 400 further includes a step (not shown) at which the output module 330 generates the notification to indicate the estimated volume of the payload in the dragline bucket 202.
[0054] In some examples, the output module 330 is the display device 332. In such examples, the step at which the output module 330 generates the notification to indicate the estimated volume of the payload in the dragline bucket 202 further includes generating the two-dimensional image indicative of the estimated volume of the payload in the dragline bucket 202, the three-dimensional image 326 indicative of the estimated volume of the payload in the dragline bucket 202, the absolute value of the estimated volume of the payload in the dragline bucket 202, and/or the percentage value of the estimated volume of the payload in the dragline bucket 202.
[0055] The method 400 also includes a step (not shown) at which the one or more processors 314 compare the estimated volume of the payload in the dragline bucket 202 with the predetermined threshold volume of payload P1. The method 400 further includes a step (not shown) at which the one or more processors 314 generate the output signal 316 if the estimated volume of the payload in the dragline bucket 202 is lesser than the predetermined threshold volume of payload P1. The method 400 further includes a step (not shown) at which the output module 330 receives the output signal 316 from the one or more processors 314. The method 400 further includes a step (not shown) at which the output module 330 generates the alert to indicate that the estimated volume of the payload in the dragline bucket 202 is lesser than the predetermined threshold volume of payload P1.
[0056] It should be noted that the steps 402, 404, 406, 408, 410 of the method 400 may be performed in a sequence that is different from that explained in relation to
[0057] While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed work machines, systems and methods without departing from the spirit and scope of the disclosure. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.