Dynamic control of an industrial machine

Patent metadata

Field	Value
Publication number	US-9361270-B2
Application number	US-201213688699-A
Country	US
Kind code	B2
Filing date	Nov 29, 2012
Priority date	Nov 29, 2011
Publication date	Jun 7, 2016
Grant date	Jun 7, 2016

Abstract

A method of controlling a digging operation of an industrial machine. The industrial machine includes a dipper, a hoist rope attached to the dipper, a hoist motor moving the hoist rope and the dipper, and a computer having a controller. The method includes monitoring a speed of the hoist motor, determining an acceleration rate of the hoist motor, comparing the acceleration rate of the hoist motor to a threshold reverse factor, determining an impact situation when the acceleration rate is less than the threshold reverse factor, and sending a reverse torque control command signal to the hoist motor.

First claim

What is claimed is:

1. A method of controlling a digging operation of an industrial machine, the industrial machine including a dipper, a hoist rope attached to the dipper, a hoist motor moving the hoist rope and the dipper, and a computer having a controller, the method comprising:
monitoring a speed of the hoist motor;
determining an acceleration rate of the hoist motor;
comparing, by the controller, the acceleration rate of the hoist motor to a threshold reverse factor;
determining, by the controller, an impact situation when the acceleration rate is less than the threshold reverse factor; and
sending, from the controller, a reverse torque control command signal to the hoist motor, based on the acceleration rate being less than the threshold reverse factor;
wherein the reverse torque control command signal includes a hoist ramp rate, the hoist ramp rate including a predetermined time period in which the speed of the hoist motor changes from a first speed to a second speed, the predetermined time period based on the comparison of the acceleration rate of the hoist motor to the threshold reverse factor.

2. The method of claim 1 , further comprising dynamically determining the hoist ramp rate.

3. The method of claim 1 , further comprising determining a torque and a speed of the hoist motor.

4. The method of claim 3 , further comprising comparing the speed of the hoist motor with a predetermined hoist motor speed value.

5. The method of claim 1 , wherein the threshold reverse factor is a threshold acceleration value associated with the acceleration of the hoist motor.

6. The method of claim 1 , wherein the threshold reverse factor is a predetermined value retrieved from a memory.

7. The method of claim 1 , wherein the threshold reverse factor is dynamically determined by the controller.

8. The method of claim 1 , further comprising setting a counter to monitor an amount of time that the reverse torque control command signal is applied.

9. The method of claim 1 , wherein the reverse torque control command signal increases a maximum allowable hoist reverse torque of the hoist motor.

10. The method of claim 9 , wherein the maximum allowable hoist reverse torque is set to a value of approximately 150% of a standard operational limit for hoist reverse torque.

11. An industrial machine comprising:
a dipper;
a hoist rope attached to the dipper;
a hoist motor operable to move the hoist rope and the dipper; and
a controller connected to the hoist motor, the controller executing programmed instructions to:
monitor a speed of the hoist motor,
determine an acceleration rate of the hoist motor,
compare the acceleration rate of the hoist motor to a threshold reverse factor,
determine an impact situation when the acceleration rate is less than the threshold reverse factor, and
send a reverse torque control command signal to the hoist motor, based on the acceleration rate being less than the threshold reverse factor;
wherein the reverse torque control command signal includes a hoist ramp rate, the hoist ramp rate including a predetermined time period in which the speed of the hoist motor changes from a first speed to a second speed, the predetermined time period based on the comparison of the acceleration rate of the hoist motor to the threshold reverse factor.

12. The industrial machine of claim 11 , wherein the controller is further configured to dynamically determine the hoist ramp rate.

13. The industrial machine of claim 11 , wherein the controller is further configured to determine a torque and a speed of the hoist motor.

14. The industrial machine of claim 13 , wherein the controller is further configured to compare the speed of the hoist motor with a predetermined hoist motor speed value.

15. The industrial machine of claim 11 , wherein the threshold reverse factor is a threshold acceleration value associated with the acceleration of the hoist motor.

16. The industrial machine of claim 11 , wherein the threshold reverse factor is a predetermined value retrieved from a memory.

17. The industrial machine of claim 11 , wherein the threshold reverse factor is dynamically determined by the controller.

18. The industrial machine of claim 11 , wherein the controller is further configured to set a counter to monitor an amount of time that the reverse torque control command signal is applied.

19. The industrial machine of claim 11 , wherein the reverse torque control command signal increases a maximum allowable hoist reverse torque of the hoist motor.

20. The industrial machine of claim 19 , wherein the maximum allowable hoist reverse torque is set to a value of approximately 150% of a standard operational limit for hoist reverse torque.

21. A method of controlling a digging operation of an industrial machine, the industrial machine including a dipper, a hoist rope attached to the dipper, a hoist motor moving the hoist rope and the dipper, and a computer having a controller, the method comprising:
determining an acceleration rate and a torque of the hoist motor;
determining, by the controller, a bail pull of the hoist motor using the acceleration rate and the torque of the hoist motor;
comparing, by the controller, the hoist motor bail pull to a hoist motor bail pull threshold;
determining, by the controller, an impact situation when the hoist motor bail pull is greater than the hoist motor bail pull threshold; and
sending, from the controller, a reverse torque control command signal to the hoist motor, based on the hoist motor bail pull being greater than the hoist motor bail pull threshold;
wherein the reverse torque control command signal includes a hoist ramp rate, the hoist ramp rate including a predetermined time period in which the speed of the hoist motor changes from a first speed to a second speed, the predetermined time period based on a comparison of the acceleration rate of the hoist motor to a threshold reverse factor.

22. The method of claim 21 , further comprising sending, from the controller, a remove torque control command signal to the hoist motor.

23. A method of controlling a digging operation of an industrial machine, the industrial machine including a dipper, a drag rope attached to the dipper, a drag motor moving the drag rope and the dipper, and a computer having a controller, the method comprising
monitoring a speed of the drag motor;
determining an acceleration rate of the drag motor;
comparing, by the controller, the acceleration rate of the drag motor to a threshold reverse factor;
determining, by the controller, an impact situation when the acceleration rate is less than the threshold reverse factor; and
sending, from the controller, a reverse torque control command signal to the drag motor, based on the acceleration rate being less than the threshold reverse factor;
wherein the reverse torque control command signal includes a drag ramp rate, the drag ramp rate including a predetermined time period in which the speed of the drag motor changes from a first speed to a second speed, the predetermined time period based on the comparison of the acceleration rate of the drag motor to the threshold reverse factor.

Assignees

• Harnischfeger Tech Inc

Inventors

• Colwell Joseph
• Lee Mooyoung

Classifications

• E02F9/2095

  Control of electric, electro-mechanical or mechanical equipment not otherwise provided for, e.g. ventilators, electro-driven fans (control of hydraulic driven equipment E02F9/22) · CPC title

• E02F9/268

  with failure correction follow-up actions · CPC title

• G06F17/00 Primary

  Digital computing or data processing equipment or methods, specially adapted for specific functions (information retrieval, database structures or file system structures therefor G06F16/00) · CPC title

• E02F3/46 Primary

  with reciprocating digging or scraping elements moved by cables or hoisting ropes {; Drives or control devices therefor (E02F3/205, E02F3/905 take precedence)} · CPC title