Method and apparatus for accurately positioning a tool on a mobile machine using on-board positioning system and off-board adjustable laser reference

[0002] The present invention pertains to the field of guidance and control systems for mobile machines. More particularly, the present invention relates to techniques for accurately positioning a tool on a mobile machine.

[0003] Various technologies have been developed to accurately position a tool on a mobile machine. These technologies are useful in applications such as construction, mining, and other industries, in which it may be necessary to maintain very tight tolerances. On a construction site, for example, it may be necessary to add or remove earth from a given location to accurately provide a specified design elevation, which may be different from the initial surface elevation. A machine such as an excavator, grader, or bulldozer equipped with a bucket, blade, or other appropriate tool is typically used. Accurate positioning of the tool is critical for achieving the required accuracy.

[0004] Some machine control systems rely upon a stationary rotating laser or a robotic total station to assist in accurately positioning the tool. However, such systems are limited to operation with only one machine at a time. In addition, laser based systems tend to be limited by line of sight. Thus, obstructions in the work area, such as other machines, may impair operation of the system. Further, many such systems are effective only when used on very level terrain. Hence, what is needed is a system for accurately positioning a tool on a mobile machine, which overcomes these and other disadvantages of the prior art.

[0005] The present invention includes a method and apparatus for enabling accurate positioning of a tool on a mobile unit operating within an area. Data representing a specified coordinate for various locations in the area are stored, and the current location of the mobile unit is determined. A command is then generated based on the current location of the mobile unit and the data. The command is transmitted from the mobile unit to a stationary device. The stationary device generates a beam and responds to the command by adjusting the beam. The beam is then detected at the mobile unit, and an adjustment of the tool is determined at the mobile unit by using the beam as a reference.

[0006] Another aspect of the present invention is a method and apparatus for enabling accurate positioning of a tool on a mobile unit, according to which a laser beam is generated to define a reference coordinate for use in positioning the tool. In particular embodiments, the reference coordinate may be an elevation. In the method, first data indicating the current location of the machine is received, and second data representing specified coordinates for a plurality of locations within the work area is maintained. The second data is accessed to determine a specified coordinate corresponding to the current location of the machine, and a coordinate of the laser beam is adjusted based on the specified coordinate to adjust the reference coordinate.

[0007] Yet another aspect of the present invention is a method and apparatus for enabling accurate positioning of a tool in a mobile unit, according to which an on-board subsystem in the mobile unit is operated in both a guidance only mode and an automatic mode. Operation in the guidance only mode includes operating the on-board subsystem to automatically compute a first adjustment of the tool, and outputting an indication of the first adjustment to an operator to guide the operator in manually positioning the tool. Operation in the automatic mode includes operating the on-board subsystem to automatically compute a second adjustment of the tool, and then automatically positioning the tool based on the second adjustment. In particular embodiments, the on-board subsystem is automatically switchable between the two modes in response to the occurrence of a predefined condition.

[0008] Still another aspect of the present invention is a method and apparatus for enabling an operator of a mobile machine operating in a work area to accurately position a tool of the machine, according to which design coordinates for a plurality of locations within the work area are stored, and the current location of the machine is determined. A desired adjustment of the tool is then automatically computed, based on the current location of the machine and the design coordinates. An indication of the computed desired adjustment is then displayed to an operator of the tool.

[0009] Other features of the present invention will be apparent from the accompanying drawings and from the detailed description which follows.

[0010] The present invention is illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like references indicate similar elements and in which:

[0011] FIG. 1 illustrates an environment including a number of stationary laser-based subsystems positioned about a mobile machine operating in a work area.

[0012] FIG. 2A is a block diagram showing an on-board subsystem in the mobile machine and a stationary subsystem according to an embodiment which uses a rotating laser beam.

[0013] FIG. 2B is a block diagram showing an on-board subsystem in the mobile machine according to an embodiment in which the processor and digital terrain model (DTM) are components of the Satellite Positioning System (SPS) receiver.

[0014] FIG. 3 is a block diagram showing an on-board subsystem in the machine and a stationary subsystem according to an embodiment which uses a scanning laser.

[0015] FIG. 4 is a block diagram showing an embodiment in which the digital terrain model (DTM) is maintained within a stationary subsystem.

[0016] FIG. 5A is a flow diagram illustrating a routine performed in the on-board subsystem of FIG. 2.

[0017] FIG. 5B is a flow diagram illustrating a routine performed in a stationary subsystem in conjunction with the routine of FIG. 5A.

[0018] FIG. 5C is a flow diagram illustrating a routine that may be performed in the on-board subsystem to switch between a guidance only mode and an automatic mode.

[0019] FIG. 6 is a flow diagram illustrating routine performed in the on-board subsystem of FIG. 3.

[0020] FIG. 7 is a flow diagram illustrating a routine performed in the stationary subsystem of FIG. 3.

[0021] FIG. 8 is a flow diagram illustrating a routine performed in the stationary subsystem of FIG. 4.

[0022] FIGS. 9A and 9B show two embodiments of a visual indicator for guiding an operator of the machine in manually positioning the tool.

[0023] A method and apparatus for accurately positioning a tool on a mobile machine are described. Briefy, the mobile machine operates within a work area about which one or more stationary laser-based subsystems are positioned. An on-board subsystem in the machine includes a processor, a satellite positioning system (SPS) receiver, a stored digital terrain model (DTM), and a photosensor for detecting a laser beam. The laser beam provides a reference level that is used to adjust the position of the tool. The onboard subsystem determines the current position of the machine using the SPS receiver and accesses the DTM to determine a design elevation corresponding to the current position. Based on the design elevation, the on-board subsystem computes a height command and transmits the height command to at least one of the laser-based stationary subsystems. Each stationary subsystem includes a laser generating a reference laser beam, a mechanism for adjusting the height of the laser beam relative to a horizontal plane, and a receiver for receiving a height command from an on-board subsystem in a mobile machine. The stationary subsystem adjusts the height of the laser according to the height command.

[0024] As will be apparent from this description, this approach provides several advantages. First, it is not necessarily limited to use with a single machine. Any machine which has such an on-board system can make use of a stationary subsystem to accurately position a tool. Also, embodiments which employ more than one of the stationary subsystems allow effective operation even when obstructions are present in the work area. Other advantages will be apparent from the description which follows.

[0025] Refer now to FIG. 1, which illustrates a mobile machine 1 operating within a work area 5. The mobile machine 1 may be, for example, an excavator, a grader, or a bulldozer. A number of laser-based stationary subsystems 6 are positioned about the work area 5. Each stationary subsystem 6 is capable of generating a laser beam 4, which can be detected by a photosensor 15 on-board the machine 1, for purposes of accurately positioning a tool 2 on the machine 1. The tool 2 may be, for example, a shovel, bucket, blade, or other tool commonly found on such machines. Although FIG. 1 shows multiple stationary subsystems 6, in a first embodiment, the machine 1 makes use of only a single stationary subsystem 6. In a second embodiment, multiple stationary subsystems 6 are employed. In either case, however, the precise elevation of the reference plane is detected by the photosensor 15 on the machine 1 for purposes of adjusting the position of the tool 2.

[0026] FIG. 2A illustrates the on-board subsystem in the machine 1 and a stationary subsystem 6, according to the first embodiment. As shown, the on-board subsystem includes a processor 10, which controls the overall operation of the on-board subsystem. The processor 10 may be or may include any device suitable for controlling and coordinating the operations of the on-board subsystem described herein, such as an appropriately programmed general or special purpose microprocessor, digital signal processor (DSP), microcontroller, an application specific integrated circuit (ASIC) or the like. Coupled to the processor 10 are: a satellite positioning system (SPS) receiver 11, which is coupled to a suitable antennae 16; a storage device 17 storing a digital terrain model (DTM) 13 of the work area 5; a tool control system 14, which is coupled to the tool 2 for controlling movement of the tool; a photosensor 15 for detecting the laser beam; and, a transmitter 12 for transmitting commands and/or data to the stationary subsystem 6 via a transmission antenna 18.

[0027] The DTM 13 includes specified design elevations (z coordinates) for multiple (x,y) locations within the work area 5. The SPS receiver 11 may be, for example, a conventional Global Positioning System (GPS) receiver such as commercially available from, for example, Trimble Navigation Limited of Sunnyvale, Calif. In other embodiments, a receiver based on another high accuracy satellite positioning system, such as the global navigation system (GLONASS) established by the former Soviet Union, may be used. In still other embodiments, the SPS receiver 11 and antenna 16 may be replaced with elements of essentially any other high accuracy positioning system, which may not necessarily be satellite based. Such positioning system may be based on pseudolites, for example, or may be an inertial navigation system (INS).

[0028] The tool control system 14 may be a standard control system for controlling movement of a tool on a mobile machine, such as currently available on the market. Tool control system 14 may include appropriate actuators and/or servo mechanisms for providing movement of the tool, as well as an appropriately programmed general or special purpose microprocessor, DSP, microcontroller, ASIC, or the like. Storage device 17 may be any device suitable for storing a volume of data sufficient to embody a DTM, such as any form of mass storage device (e.g., magnetic or optical disk), random access memory (RAM), read only memory (ROM), flash memory, or a combination of such devices. Note that the on-board subsystem may also include one or more additional memory devices (not shown) of the types just mentioned for storing program instructions for processor 10 and/or other data. Display device 20 may be a cathode ray tube (CRT), liquid crystal display (LCD), or the like, or a more simple type of display, such as one or more light emitting diodes (LEDs), light bulbs, etc.

[0029] In certain embodiments, the SPS receiver 11 may be equipped to store the DTM 13 and/or to perform some or all of the functions of processor 10, which are described further below. Such an embodiment is illustrated in FIG. 2B. Hence, the DTM 13 and the processor 10 may be components of the SPS receiver 11, as shown. Such embodiments may therefore reduce the amount of hardware required in the on-board subsystem, and therefore reduce the size and complexity of the system. The SPS receiver 11 in such an embodiment may be, for example, a GPS receiver, as indicated above.

[0030] As shown in FIGS. 2A and 2B, the stationary subsystem 6 includes a laser 29 for generating the laser beam 4, a rotation drive 28 for rotating the laser 29, a height controller 26 coupled to the receiver 25, a height servo mechanism coupled to the height controller 26 and the laser 29, and, an antenna 30, and suitable for receiving commands and/or data from the on-board subsystem of the machine 1. The rotation drive 28 rotates the laser 29 about a vertical axis to cause the rotated laser beam 4 to define a horizontal reference plane. The laser 29 is mounted on a vertically telescoping mast or other suitable mechanism for enabling the height of the laser beam to be adjusted relative to a fixed reference level. The height is adjusted in this embodiment by the servo mechanism 27 based upon a height command transmitted by the on-board subsystem and received by receiver 25. In particular, when received, the height command is used by the height controller 26 to signal the height servo mechanism 27 to adjust the vertical position of the rotating laser beam by an amount indicated by the height command.

[0031] Referring now to FIGS. 5A and 5B, the operation of the first embodiment will now be described. FIG. 5A shows a routine performed in the on-board subsystem, while FIG. 5B shows a corresponding routine performed within the stationary subsystem 6. As the mobile machine 1 moves about the work area 5, the on-board subsystem uses the SPS receiver 11 to determine the current (x,y,z) position coordinates of the machine 1 at block 501. At block 502, the processor uses the current position coordinates to access the DTM 13 to determine the design elevation (z coordinate) for the current (x,y) position of the machine. The processor 10 then computes a height command based upon the difference between the design elevation and the actual elevation of the machine 1 at block 503. To provide high accuracy, computation of the height command is also based on knowledge of the precise location at which the SPS antenna 16 is mounted on the machine 1 and knowledge of the precise manner in which the tool 2 is mounted to the machine 1. Such knowledge is maintained by the on-board subsystem in any suitable form. Once the height command is computed, at block 504 the processor 10 causes the height command to be transmitted by transmitter 12 via antenna 18 over a wireless communication link 33 to the subsystem 6 (see FIG. 2). Link 33 may be, for example, a radio frequency (RF) link. In other embodiments, link 33 may be an optical (e.g., infrared, laser, etc.) link or any other link suitable for communicating commands and/or data between a mobile machine and a stationary subsystem.

[0032] Referring now to FIG. 5B, if the height command is received by the stationary subsystem 6 at block 521, then at block 522 the height control unit 26 causes the servo mechanism 27 to adjust the height of the laser beam 4 relative to some reference level based on the height command. Referring again to FIG. 5A, upon detection at block 505 of the rotating laser beam 4 by photosensor 15, which is sensitive to the vertical coordinate of the laser beam 4, processor 10 computes the required adjustment amount for tool 2 at block 506. If the laser beam is not detected, the routine repeats from block 504 with retransmission of the height command or an appropriate error recovery routine.

[0033] Following determination of the adjustment amount, at block 507 the processor 10 may signal the tool control system 14 to adjust the position of the tool 2 according to the computed adjustment amount, such that the position of the tool 2 is automatically adjusted by the on-board subsystem. Alternatively, block 507 may simply entail causing the display 20 to indicate the required adjustment to the operator of the machine 1. In particular, it may be desirable in some cases for the on-board subsystem to automatically position the tool 2 according to the computed adjustment amount. In other cases, however, it may be desirable to allow the operator of the machine 1 to adjust the tool, with guidance from the on-board subsystem. Such guidance can be provided in the form of a visual, audible, or other suitable indication of the adjustment amount, as will be discussed below. Accordingly, block 507 may entail merely generating a visual display or other indication according to the computed adjustment amount, rather than automatically adjusting the tool. Note that in the guidance only mode, the on-board subsystem does not necessarily have to detect the laser beam. The indication provided to the operator may be based entirely upon the SPS based elevation and the DTM 13.

[0034] In some embodiments, it may be desirable to provide both an automatic mode, in which the on-board subsystem automatically adjusts the position of the tool, and a guidance only mode, in which the on-board subsystem merely provides the aforementioned indication to the operator. FIG. 5C shows a routine illustrating how such capability may be applied. Specifically, the on-board subsystem may be operated in guidance only mode at block 521 for purposes of performing rough (approximate) cutting operations. Upon sensing the difference between the current elevation and the design elevation drop below a predetermined threshold value at block 522, the onboard subsystem automatically switches to automatic mode at block 524. The on-board subsystem then is operated in the automatic mode to control fine (precise) operation of the tool 2.

[0035] FIGS. 9A and 9B show simple examples of visual indicators that may be used for this purpose. Such visual indicators may be embodied as the display device 20 (FIGS. 2A and 2B) or as graphical representations output by the display device 20. FIG. 9A shows a visual indicator including segments 31 and 32, which light up appropriately to indicate that the operator should adjust the tool up or down, respectively. FIG. 9B illustrates a visual indicator for an embodiment which allows two-dimensional positioning of the tool. The indicator of FIG. 9B includes a vertical indicator 35 and a horizontal indicator 36 containing movable beads 37 and 38, respectively, to indicate to the operator how much to adjust the tool up/down or left/right, respectively.

[0036] As noted above, certain embodiments of the present invention may employ multiple stationary laser-based subsystems 6 positioned abut the work area 5, as shown in FIG. 1, rather than only one stationary subsystem. Multiple stationary subsystems may be advantageous, for example, when a machine 1 goes out of the line of sight of a given stationary subsystem. The on-board subsystem can be configured to automatically select an alternate stationary subsystem in such cases. The use of multiple stationary subsystems also allows multiple machines to simultaneously use the techniques described herein, as described further below.

[0037] When multiple stationary subsystems are used, it may be desirable to use scanning lasers (i.e., lasers capable of automatically aiming and locking onto a target) rather than rotating lasers. Scanning lasers are well-known, commercially available products. An embodiment which employs multiple stationary subsystems equipped with scanning lasers will now be described. In this embodiment, the DTM 13 includes the exact (x,y) location of each of the stationary subsystems 6, in addition to specified design elevations for the work area 5. Further, each stationary subsystem 6 is assigned a unique identifier. The identifiers of the stationary subsystems are stored in the onboard subsystem of the machine 1 in any suitable format. For example, identifiers similar to Ethernet addresses may be used. Each identifier may be embodied in a simple message header for a data stream broadcast over link 33.

[0038] In operation, the on-board subsystem, knowing the exact location of the machine 1 and each stationary subsystem 6, broadcasts a message including the identifier of the closest stationary subsystem and the current position of the machine. The message is ignored by all stationary subsystems except the one whose identifier was transmitted. The identified subsystem uses the position coordinates of the machine to aim the scanning laser to lock onto the photosensor 15 of the machine 15.

[0039] Referring to FIG. 3, in one embodiment which employs a scanning laser, the stationary subsystem 6 includes an aiming servo 32 coupled to the laser 29 for aiming the laser 29. Aiming servo 32 is also coupled to a processor 32, which is also coupled to the receiver 25 and to the height servo 27. Processor 32 may be an appropriately programmed general or special purpose microprocessor, DSP, microcontroller, ASIC, or the like.

[0040] Referring now to FIGS. 6 and 7, upon determining the current position of the machine 1 at block 601, the processor 10 of the on-board subsystem accesses the DTM 13 at block 602 to identify the closest stationary subsystem 6 and selects that stationary subsystem. At block 603, the processor 10 computes a height command in the same manner as described above. After selecting the closest stationary subsystem, at block 604 the processor 10 causes transmitter 12 to transmit the height command, the current position coordinates of the machine 1, and the identifier of the selected stationary subsystem 6. Upon receiving the transmitted information at block 701 (FIG. 7), the processor 32 of the stationary subsystem 6 determines at block 702 whether the transmitted identifier matches the identifier assigned to that subsystem. If not, the transmission is ignored at block 703. If the transmitted identifier matches the assigned identifier, then at block 704 the stationary subsystem 6 adjusts the height of the laser beam according to the height command in the transmission, and processor 32 further controls the aiming servo 32 to cause the laser 29 to achieve a lock on the photosensor 15 of the machine 1.

[0041] Referring again to FIG. 6, if the laser beam is detected by the on-board subsystem within a predefined period of time at block 605, then at block 606 the processor 10 of the on-board subsystem determines an appropriate adjustment amount for the laser beam based upon the position at which the beam is detected on photosensor 15. At block 607, the position of the tool 2 is adjusted based on the computed adjustment amount, or an appropriate indication is provided to the operator.

[0042] At block 605, if the laser beam is not detected within a predefined period of time (e.g., the beam is obstructed or the selected subsystem is malfunctioning), then at block 608 the processor 10 accesses the DTM 13 to identify and select the next closest stationary subsystem 6. The routine then repeats from block 604 using the newly selected subsystem.

[0043] In certain embodiments, the DTM 13 may be stored off-board, rather than in the on-board subsystem. For example, the DTM 13 may be stored in one or more of the stationary subsystems 6, as shown in FIG. 4, or in a processing device that is physically separate from the stationary subsystems 6. The separate processing device might be, for example, a conventional computer or a GPS base station, which is configured to communicate with the stationary subsystems 6 over a network or other suitable link. Such a link may be a wireless link.

[0044] In one embodiment in which the DTM 13 is stored off-board, the on-board subsystem transmits only the current (x,y,z) position coordinates of the machine. The stationary subsystem 6 or other device storing the DTM 13 receives the transmitted coordinates and responds by accessing the DTM 13 to determine the design elevation for the machine's current location and (if appropriate) the stationary subsystem closest to the machine. The closest stationary subsystem is then caused to adjust its laser accordingly.

[0045] FIG. 8 illustrates a routine that may be performed in a stationary subsystem 6 storing the DTM 13. It will be recognized that this routine may be easily adapted, if necessary, to better suit embodiments in which the DTM 13 is stored in a separate processing device. Initially, the on-board subsystem in the machine transmits the current (x,y,z) position coordinates of the machine to the stationary subsystem 6. After such transmission, at block 801, if the stationary subsystem 6 has received the position coordinates of a mobile machine, then at block 802 the stationary subsystem 6 accesses the DTM 13 to determine the design elevation corresponding to the current position of the machine 1. Next, at block 803 the stationary subsystem 6 computes the appropriate height of the laser beam based on the current elevation of the machine 1 and the design elevation for the current (x,y) position of the machine 1. At block 804, the height of the laser beam is adjusted based on the computed height, and if the laser is a scanning laser, it is operated to lock onto the photosensor 15 of the machine 1 using the received position coordinates.

[0046] As noted above, the use of multiple stationary subsystems also allows multiple mobile machines to simultaneously position their tools using the techniques described above. Each such machine may equipped with an on-board subsystem as described above. Thus, each machine can use a different stationary subsystem, e.g., the subsystem to which it is closest.

[0047] In a multiple-machine, multiple stationary subsystem environment, the DIM 13 may be stored off-board, such as in a stationary subsystem or a separate processing device. In one embodiment, each machine is assigned a unique identifier. The format of such an identifier may be any suitable format, such as described above. From time to time, each machine transmits its identifier along with its position coordinates. The stationary subsystem 6 or other device storing the DTM 13 receives the identifiers and position data from the machines, accesses the DTM 13, and assigns each of the machines to an appropriate stationary subsystem. The assignments may be made based on the relative positions of the machines and the stationary subsystems 6. The stationary subsystem or other device storing the DTM 13 then transmits information to direct each stationary subsystem to adjust its laser accordingly and/or to inform each mobile machine of its assigned stationary subsystem.

[0048] Thus, a method and apparatus for accurately positioning a tool on a mobile machine have been described. Although the present invention has been described with reference to specific exemplary embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the invention as set forth in the claims. Accordingly, the specification and drawings are to be regarded in an illustrative sense rather than a restrictive sense.