System and method for managing carryback thresholds in surface haulage

{
  "publication_number": "US10968602B2",
  "country": "US",
  "kind": "B2",
  "title": "System and method for managing carryback thresholds in surface haulage",
  "abstract": "A machine routing and planning system for mobile machines at a work site includes a plurality of haul trucks, at least one loading machine, and a controller. The controller is configured to generate an initial material movement plan based upon an initial number of loading machines and haul trucks and the initial carryback threshold, and generate initial movement command signals to operate the loading machines and haul trucks at the work site based upon the initial material movement plan. The controller is further configured to generate a modified material movement plan based upon a modified number of loading machines and haul trucks and the modified carryback threshold, and generate modified movement command signals to operate the loading machines and haul trucks at the work site based upon the modified material movement plan.",
  "claims": [
    "1. A machine routing and planning system for mobile machines at a work site, the system comprising: a plurality of haul trucks, each haul truck having a dump body for hauling material, the dump body having an interior surface; at least one loading machine for loading material into the dump body of each haul truck; and a controller configured to: access an initial number of loading machines and haul trucks operating at the work site; access an initial carryback threshold for the interior surface of each haul truck based on the initial number of loading machines and haul trucks operating at the work site; generate an initial material movement plan based upon the initial number of loading machines and haul trucks and the initial carryback threshold; generate initial movement command signals to operate the loading machines and haul trucks at the work site based upon the initial material movement plan; access a modified number of loading machines and haul trucks operating at the work site; access a modified carryback threshold for the interior surface of each haul truck based on the modified number of loading machines and haul trucks operating at the work site; generate a modified material movement plan based upon the modified number of loading machines and haul trucks and the modified carryback threshold; and generate modified movement command signals to operate the loading machines and haul trucks at the work site based upon the modified material movement plan.",
    "2. The system of claim 1, wherein the modified carryback threshold is greater than the initial carryback threshold upon a decrease in a number of haul trucks operating at the work site without a change in a number of loading machines operating at the work site.",
    "3. The system of claim 1, wherein the modified carryback threshold is less than the initial carryback threshold upon an increase in a number of haul trucks operating at the work site without a change in a number of loading machines operating at the work site.",
    "4. The system of claim 1, wherein a difference between the initial carryback threshold and the modified carryback threshold is linear relative to a change in a number of haul trucks operating at the work site.",
    "5. The system of claim 1, wherein a difference between the initial carryback threshold and the modified carryback threshold is nonlinear relative to a change in a number of haul trucks operating at the work site.",
    "6. The system of claim 1, wherein each material movement plan is determined based upon a cost of operating each machine.",
    "7. The system of claim 6, wherein the cost of operating each machine is expressed as a cost per unit time.",
    "8. The system of claim 6, wherein the cost of operating each machine is expressed as a cost based on quantity of material moved.",
    "9. The system of claim 8, wherein the cost based on quantity of material moved is expressed as a cost per unit volume.",
    "10. The system of claim 9, wherein the cost based on quantity of material moved is expressed as a cost per unit weight.",
    "11. The system of claim 1, further comprising a carryback monitoring system to determine an amount of carryback material within the dump body of each haul truck.",
    "12. The system of claim 11, wherein each material movement plan is based upon an effective volume of the dump body of each haul truck.",
    "13. The system of claim 11, wherein each material movement plan includes designating each haul truck for a clean out operation upon the amount of carryback material exceeding a current carryback threshold, and directing a haul truck to a clean out station after designating the haul truck for the clean out operation.",
    "14. The system of claim 13, wherein each material movement plan includes directing haul trucks to the clean out station based upon a prioritization scheme.",
    "15. A method of machine routing and planning for mobile machines at a work site comprising: accessing an initial number of loading machines and haul trucks operating at the work site, each haul truck having a dump body for hauling material, the loading machines configured for loading material into the dump body of each haul truck; accessing an initial carryback threshold for an interior surface of each haul truck based on the initial number of loading machines and haul trucks operating at the work site; generating an initial material movement plan based upon the initial number of loading machines and haul trucks and the initial carryback threshold; generating initial movement command signals to operate the loading machines and haul trucks at the work site based upon the initial material movement plan; accessing a modified number of loading machines and haul trucks operating at the work site; accessing a modified carryback threshold for the interior surface of each haul truck based on the modified number of loading machines and haul trucks operating at the work site; generating a modified material movement plan based upon the modified number of loading machines and haul trucks and the modified carryback threshold; and generating modified movement command signals to operate the loading machines and haul trucks at the work site based upon the modified material movement plan.",
    "16. The method of claim 15, wherein upon a decrease in a number of haul trucks operating at the work site without a change in a number of loading machines operating at the work site, increasing the initial carryback threshold to define the modified carryback threshold.",
    "17. The method of claim 15, wherein upon an increase in a number of haul trucks operating at the work site without a change in a number of loading machines operating at the work site, decreasing the initial carryback threshold to define the modified carryback threshold.",
    "18. The method of claim 15, further comprising determining an amount of carryback material within the dump body of each haul truck.",
    "19. The method of claim 18, further comprising designating each haul truck for a clean out operation upon the amount of carryback material exceeding a current carryback threshold and directing a haul truck to a clean out station after designating the haul truck for the clean out operation.",
    "20. The method of claim 15, further comprising determining an amount of carryback material within the dump body of each haul truck and generating each material movement plan based upon an effective volume of the dump body of each haul truck."
  ],
  "description_excerpt": "This disclosure relates generally to mobile haul machines for moving material and, more particularly, to a system for operating haul machines through the management of carryback thresholds with respect to carryback material within the dump body of the haul machine.\n\nMachines such as haul trucks or haul machines are used in various industries to transport or move material from one location to another. When using a haul truck to haul material, under certain conditions, some of the material may adhere or stick to the interior surface of the dump body of the haul truck after each dumping operation. The material remaining in the dump body may be referred to by different terms such as carry back, residual load, or deadbed.\n\nCarryback material remaining in the dump body is undesirable because it reduces machine productivity. More specifically, carryback material reduces the effective capacity (e.g., volume) of the dump body thus requiring a greater number of haul cycles to move a desired amount of material from the loading site to the dump site. Further, the increased weight of the dump body due to carry back material also reduces the fuel efficiency of the haul trucks. Each of these decreases the efficiency of the material moving process.\n\nU.K. Patent Application No. 2537590 discloses a tipper truck having tipper body that may be pivoted by a hydraulic cylinder to empty the tipper body. A pressure parameter is measured relating to the hydraulic pressure of the hydraulic cylinder. A residual load may be measured within the tipper body based upon the pressure parameter.",
  "cpc": [
    "E02F 9/2054",
    "B60P 1/04",
    "B60S 3/04",
    "E02F 7/00",
    "E02F 9/205",
    "G01C 21/34",
    "G05D 1/0212",
    "G05D 1/0287",
    "G05D 2201/0202",
    "G05D 2201/021",
    "G06Q 10/04",
    "G06Q 10/06315",
    "G06Q 10/0832",
    "G06Q 50/02",
    "G06Q 50/08"
  ],
  "ipc": [
    "B60P 1/04",
    "E02F 7/00",
    "E02F 9/20",
    "G01C 21/34",
    "G05D 1/02",
    "G06Q 10/06",
    "B60S 3/04"
  ],
  "assignees": [
    "Caterpillar Inc"
  ],
  "inventors": [
    "Carl F. B. Hendricks"
  ],
  "filing_date": "2019-01-30",
  "publication_date": "2021-04-06",
  "grant_date": "2021-04-06",
  "priority_date": "2019-01-30",
  "application_number": "US-201916262126-A",
  "family_id": "69591778",
  "cited_by_count": 13,
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}