SYSTEM AND METHOD FOR UNDERWATER PAYLOAD ESTIMATION IN DRAGLINE BUCKET

TECHNICAL FIELD

[0001]The present disclosure relates to a dragline machine, and more particularly, to a system for underwater payload estimation in a dragline bucket of the dragline machine and a method of underwater payload estimation in the dragline bucket of the dragline machine.

BACKGROUND

[0002]Dragline machines, such as dragline excavators are widely used in mining and earthmoving operations due to their capability to handle large volumes of materials. These draglines machines typically include a dragline bucket associated therewith. The dragline bucket may be used to excavate, hold, and transport materials, such as rocks, aggregates, and other payloads. While dragline machines are highly effective in overburden applications, their productivity significantly diminishes in underwater applications due to lack of visibility for operators.

[0003]When the dragline bucket is submerged underwater, the operator's ability to accurately judge the material loading inside the dragline bucket is compromised due to opaque nature of the water. This lack of visibility forces operators to rely on intuition and experience for underwater payload estimation, resulting in increased cycle time or underfilled draglines buckets, thereby leading to decrease in a productivity at a worksite. Therefore, there is a need for a system to accurately estimate the payload in the dragline bucket of the dragline machines, when the dragline bucket is underwater.

[0004]U.S. Pat. No. 4,791,738 describes a method and apparatus for determining a load of an excavator bucket. For determining, the load of the excavator bucket, or optionally of another holding region, a measurement step and an evaluation step are carried out. In the measurement step, the position of a load surface is determined by a noncontact distance-measuring device, and, in the evaluation step, a load volume is determined from the position of the load surface and the position and shape of the excavator bucket or of the holding region. For determining the position of the load surface, at least one two-dimensional matrix with distance values is created by means of a distance-measuring camera. For determining the position of the excavator bucket, the distances to at least three points of the excavator bucket, in particular to points on the upper bucket edge, optionally to marked points are determined using the distance-measuring apparatus for determining the surface.

SUMMARY OF THE DISCLOSURE

[0005]In an aspect of the present disclosure, a system for underwater payload estimation in a dragline bucket of a dragline machine is provided. The system 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 also 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 also 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 from the sensing module. The at least one processor is further configured to generate an output signal indicative of the estimated volume of the payload in the dragline bucket.

[0006]In another aspect of the present disclosure, a dragline machine is provided. The dragline machine includes a frame. The dragline machine also includes a dragline bucket. The dragline machine further includes a system for underwater payload estimation in the dragline bucket. The system 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 also 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 also 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 from the sensing module. The at least one processor is further configured to generate an output signal indicative of the estimated volume of the payload in the dragline bucket.

[0007]In yet another aspect of the present disclosure, a method of underwater payload estimation in a dragline bucket of a dragline machine is provided. The method includes disposing a sensing module on the dragline bucket. The method also includes generating, by the sensing module, a plurality of signals indicative of a distance value between the sensing module and payload in the dragline bucket. The method further includes 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. The at least one processor is communicably coupled with at least one memory of the controller and the sensing module. The method includes 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. The method also includes generating, by the at least one processor, an output signal indicative of the estimated volume of the payload in the dragline bucket.

[0008]Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009]FIG. 1 is a schematic side view of a dragline machine, according to an example of the present disclosure;

[0010]FIG. 2 is a perspective view of a dragline bucket of the dragline machine of FIG. 1 with a sensing module disposed at an exemplary location, according to an example of the present disclosure;

[0011]FIG. 3 is a perspective view of the dragline bucket of the dragline machine of FIG. 1 with the sensing module disposed at an exemplary location, according to another example of the present disclosure;

[0012]FIG. 4 is a perspective view of a dragline bucket of the dragline machine of FIG. 1 with a pair of sensing modules disposed at exemplary locations, according to yet another example of the present disclosure;

[0013]FIG. 5A illustrates a block diagram of a system for underwater payload estimation in the dragline bucket of FIG. 2, according to an example of the present disclosure;

[0014]FIG. 5B illustrates a perspective view of an exemplary sensing module associated with the system of FIG. 5A, according to an example of the present disclosure;

[0015]FIG. 6 is a pictorial representation of a notification indicating the estimated volume of payload in the dragline bucket as depicted on an output device of the system of FIG. 5A, according to an example of the present disclosure;

[0016]FIG. 7 illustrates a block diagram of a system, including a wireless communication device, for underwater payload estimation in the dragline bucket of FIG. 2, according to another example of the present disclosure; and

[0017]FIG. 8 is a flowchart for a method of underwater payload estimation in the dragline bucket of the FIG. 1, according to an example of the present disclosure.

DETAILED DESCRIPTION

[0018]Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

[0019]FIG. 1 illustrates a schematic side view of an exemplary dragline machine 100. The dragline machine 100 is embodied as a dragline excavator herein. Alternatively, the dragline machine 100 may include another type of earthmoving machine used to perform underwater material removal or excavation. The dragline machine 100 may perform one or more operations associated with an industry, such as mining, construction, forestry, farming, transportation, or any other industry known in the art. The dragline machine 100 may be embodied as a manual, an autonomous, or a semi-autonomous machine, without any limitations.

[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 FIGS. 2 to 4, perspective views of the dragline bucket 202 are shown. The dragline bucket 202 includes a base 204 (best visible in FIG. 3) and a number of side walls 206. Specifically, the dragline bucket 202 includes three side walls 206. The base 204 and the side walls 206 together define a material receiving space 208 of the dragline bucket 202. Further, the dragline bucket 202 includes an arch 210 extending arcuately between the opposite side walls 206. The dragline bucket 202 further includes a dump bracket 212 attached centrally to the arch 210. The dragline bucket 202 is coupled to the dragline machine 100 via the dump bracket 212.

[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 FIG. 5A, the dragline machine 100 further includes a system 300 for underwater payload estimation in the dragline bucket 202 (see FIG. 2 to 4). The system 300 includes a sensing module 302 disposed on the dragline bucket 202. The sensing module 302 generates a number of signals 304 indicative of a distance value between the sensing module 302 and payload in the dragline bucket 202. The sensing module 302 is connected with a controller 310 (of the system 300) via a wired connection or a wireless connection. In the example illustrated in FIG. 5A, the sensing module 302 is connected with the controller 310 via the wired connection.

[0027]Referring again to FIG. 2, in an example, the sensing module 302 may include a single sensing module 302 that is disposed centrally on the arch 210 of the dragline bucket 202. In the illustrated example of FIG. 2, the sensing module 302 is coupled with the arch 210 via a support structure 303. The support structure 303 may include a hollow box that facilitates coupling of the sensing module 302 with the arch 210. The support structure 303 may be made of a material that has high impact resistance. The support structure 303 may be made of a polymer, a metal, or an alloy, without any limitations.

[0028]Referring to FIG. 3, in another example, the sensing module 302 may include the single sensing module 302 that is disposed offset from the dump bracket 212 on the arch 210. Similarly, the sensing module 302 may be attached on another side of the dump bracket 212 on the arch 210.

[0029]Referring to FIG. 4, in yet another example, two sensing modules 302 may be disposed symmetrically on either side of the dump bracket 212 of the dragline bucket 202. Accordingly, the number and position of the sensing module 302 may vary and depend on application requirements.

[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 FIG. 5A, the system 300 further includes the controller 310. The controller 310 includes one or more memories 312 and one or more processors 314 communicably coupled with the one or more memories 312 and the sensing module 302. The one or more processors 314 receive, from the sensing module 302, the number of signals 304 indicative of the distance value between the sensing module 302 and the payload in the dragline bucket 202 (see FIGS. 2 to 4), when the dragline bucket 202 is underwater.

[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 FIG. 5B, the sensing module 302 is embodied as the sonar sensor. Further, the sensing module 302 includes a housing 336. The housing 336 may house various sensing components of the sensing module 302, such as, transducers. The housing 336 may be made from a material that has a high hardness value, a high tensile strength, a high compressive yield strength, a high tear strength to withstand tear, and a high impact strength to withstand sudden impact forces. Further, the housing 336 may be made of a material that prevents sticking of foreign particles, such as, mud or dirt thereon. The housing 336 includes a generally cylindrical shape and has a stepped design herein. Alternatively, the housing 336 may have a square shape or a rectangular shape.

[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 FIG. 5A), the first portion 338 protrudes out from the support structure 303 and the second portion 340 is received within the support structure 303. The housing 336 may be made of a polymer. In an example, the first portion 338 may be made from elastomeric polyurethane. Moreover, a material of the first and second portions 338, 340 may be different or the material of the first and second portions 338, 340 may be the same. It should be noted that the present disclosure is not limited by a type, a location, a size, or a design of the sensing module 302.

[0036]Referring back to FIG. 5A, the system 300 further includes an output module 330 communicably coupled with the one or more processors 314. The output module 330 receives the output signal 316 from the one or more processors 314 and generates a notification to indicate the estimated volume of the payload in the dragline bucket 202.

[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 FIG. 7) of the dragline machine 100 or within a remote operator station/back-office. Further, the notification includes a two-dimensional image indicative of the estimated volume of the payload in the dragline bucket 202, a three-dimensional image 326 (shown in FIG. 6) indicative of the estimated volume of the payload in the dragline bucket 202, an absolute value of the estimated volume of the payload in the dragline bucket 202, and/or a percentage value of the estimated volume of the payload in the dragline bucket 202. In an example, the notification may indicate that the dragline bucket 202 is filled with one ton of payload. In another example, the notification may indicate that the dragline bucket 202 is filled up to 75% of a total available volume of the dragline bucket 202, and so on.

[0038]As shown in FIG. 6, the exemplary three-dimensional image 326 indicative of the estimated volume of the payload in the dragline bucket 202 is illustrated. The three-dimensional image 326 is a pictorial representation of the dragline bucket 202 underwater and loaded with the payload. As seen from FIG. 6, the dragline bucket 202 is not completely filled with the payload and may be loaded with some additional payload. In such examples, the three-dimensional image 326 may notify the operators that the dragline bucket 202 may be further loaded with the payload to realize a full capability of the dragline bucket 202. It should be noted that the present disclosure is not limited to a type of notification that is generated to notify the operators regarding the amount of the payload in the dragline bucket 202.

[0039]Referring to FIG. 5A, the one or more processors 314 further compares the estimated volume of the payload in the dragline bucket 202 with a predetermined threshold volume of payload P1. The predetermined threshold volume of payload P1 may be stored in the memories 312. The one or more processors 314 also 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 one or more processors 314 further transmit the output signal 316 to the output module 330.

[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 FIG. 7, another example of the system 300 is illustrated. In this example, the sensing module 302 is connected with the controller 310 via the wireless connection. Specifically, when the sensing module 302 is connected with the controller 310 via the wireless connection, the system 300 further includes a transmitter 322 disposed on the dragline bucket 202 (see FIGS. 2 to 4), and a receiver 324 disposed on the dragline machine 100 and external to the dragline bucket 202. For example, the receiver 324 may be disposed within the operator cabin 142 of the dragline machine 100. In some examples, the operator may be seated inside the operator cabin 142 to control the dragline machine 100. The transmitter 322 and the receiver 324 together form a wireless communication device 320 of the system 300. The transmitter 322 receives a signal from the sensing module 302 and wirelessly transmits the signal to the receiver 324. Further, the receiver 324 transmits the signal 304 to the processors 314. It should be noted that an operation of the system 300 depicted in FIG. 7 is same as the operation of the system 300 depicted and explained in FIG. 5A.

[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.

[0048]FIG. 8 illustrates a flowchart for the method 400 of underwater payload estimation in the dragline bucket 202 of the dragline machine 100. At step 402, the sensing module 302 is disposed on the dragline bucket 202.

[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 FIG. 8. Further, various steps 402, 404, 406, 408, 410 can be performed together.

[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.