Realtime payload mapping for loader/hauler system optimization

Abstract

A payload optimization system is disclosed and may include one or more visual sensors operably coupled to a hauling machine and configured to scan and produce a payload body data set. The system may further include a loading machine including a payload bucket configured to load a payload into the payload body. Moreover, a loading system controller may be communicably coupled to each of the hauling machine and the loading machine and configured to identify the hauling machine and the loading machine using a set of machine identifiers. Moreover, the controller may receive the payload body data set from the one or more visual sensors, generate a payload body map, and program a loading sequence of the payload body based on the payload body map. The loading system controller may transmit and display the loading sequence configured to guide a loading cycle between the hauling machine and the loading machine.

What is claimed is: 
     
         1 . A payload optimization system for loading a set of work machines, the payload optimization system comprising:
 one or more visual sensors operably coupled to a hauling machine, the one or more visual sensors configured to scan a payload body of the hauling machine and produce a payload body data set;   a loading machine including a payload bucket configured to load a payload into the payload body of the hauling machine;   a loading system controller communicably coupled to each of the hauling machine and the loading machine, the loading system controller configured to:
 identify the hauling machine and the loading machine using a set of machine identifiers received from the hauling machine and the loading machine; 
 receive the payload body data set from the one or more visual sensors; 
 generate a payload body map based on the payload body data set; 
 program a loading sequence of the payload body based on the payload body map and transmit the loading sequence to the loading machine; and 
 display the loading sequence on a loading machine display device, the loading sequence configured to guide a loading cycle between the hauling machine and the loading machine. 
   
     
     
         2 . The payload optimization system of  claim 1 , wherein the loading system controller is further configured to analyze the payload body data set to confirm the payload body is empty and transmits a start signal to the loading machine to begin the loading sequence. 
     
     
         3 . The payload optimization system of  claim 1 , wherein the loading sequence is programmed to identify a first target dump zone for a first payload delivered to the payload body and transmitting the first target dump zone to the loading machine. 
     
     
         4 . The payload optimization system of  claim 3 , wherein the one or more visual sensors are configured to scan the payload body in a continuous scanning mode to produce a continuous scanning data set including a placement of the first payload, wherein the loading sequence incorporates the continuous scanning data set to identify one or more additional target dump zones for one or more additional loads delivered to the payload body, wherein the one or more additional target dump zones are communicated to the loading machine and continuously updated based on the continuous scanning data set. 
     
     
         5 . The payload optimization system of  claim 4 , further comprising at least one pressure sensor operably coupled to the hauling machine and configured to monitor and collect a suspension pressure, wherein the loading sequence incorporates the continuous data set and the suspension pressure such that the one or more additional target dump zones are continuously updated to produce a balanced payload within the payload body. 
     
     
         6 . The payload optimization system of  claim 4 , further including one or more payload monitoring sensors operably coupled to the loading machine and configured to monitor a load volume and load density of the payload in the payload bucket, wherein the load volume and load density are transmitted to the loading system controller and the loading sequence incorporates the load volume and load density to identify the one or more additional target dump zones. 
     
     
         7 . The payload optimization system of  claim 1 , wherein the loading system controller is configured to generate an event log based on the loading sequence, the event log includes one or more events performed by the hauling machine and the loading machine, wherein the event log is analyzed to determine an amount of work performed by the hauling machine and the loading machine. 
     
     
         8 . A method of optimizing a payload position within a work machine, the method comprising:
 identifying a hauling machine and a loading machine using one or more visual sensors coupled to a frame of the hauling machine;   receiving a payload capacity of the hauling machine from a machine specification data base based on an identification of the hauling machine;   receiving a loading capacity of the loading machine from the machine specification data base based on an identification of the loading machine;   scanning a payload body of the hauling machine with the one or more visual sensors to produce a payload body data set;   generating a payload body map based on the payload body data set;   programming a loading sequence of the payload body based on the payload body map and the loading capacity of the loading machine; and   transmitting the loading sequence to the loading machine to guide a loading cycle of the hauling machine.   
     
     
         9 . The method of  claim 8 , wherein scanning the payload body further includes identifying the payload body is empty and the hauling machine is ready to begin the loading cycle. 
     
     
         10 . The method of  claim 8 , wherein programming the loading sequence includes identifying a first target dump zone for a first payload delivered to the payload body and transmitting the first target dump zone to the loading machine. 
     
     
         11 . The method of  claim 10 , wherein operating the one or more visual sensors in a continuous scanning mode produces a continuous scanning data set including a placement of the first payload, and programming the loading sequence incorporates the continuous scanning data set to identify one or more additional target dump zones for one or more additional loads delivered to the payload body and transmitting the one or more additional target dump zones to the loading machine. 
     
     
         12 . The method of  claim 11 , further comprising at least one pressure sensor operably coupled to the hauling machine and configured to monitor and collect a suspension pressure, wherein programming the loading sequence incorporates analyzing the continuous scanning data set and the suspension pressure such that the one or more additional target dump zones are continuously updated to produce a balanced payload within the payload body. 
     
     
         13 . The method of  claim 11 , further comprising one or more payload monitoring sensors operably coupled to the loading machine and configured to monitor a load volume and load density, wherein programming the loading sequence incorporates the load volume and load density to identify the one or more additional target dump zones. 
     
     
         14 . The method of  claim 8 , wherein programming the loading sequence includes generating an event log capturing one or more events performed by the hauling machine and the loading machine, and the event log is analyzed to determine an amount of work performed by the hauling machine and the loading machine. 
     
     
         15 . A controller for optimizing an operation of a work machine, the controller comprising:
 a machine specification module including a payload capacity for a hauling machine and a loading capacity for a loading machine;   a vision data module configured to receive a visual data set collected from one or more visual sensors operably coupled to the hauling machine, the one or more visual sensors configured to scan a payload body of the hauling machine and produce a payload body data set;   a payload mapping module configured to receive the payload body data set and generate a payload body map;   a loading sequence module configured to program a loading sequence of the payload body of the hauling machine based on the payload body map and the loading capacity; and   a communication module configured to transmit the loading sequence to the loading machine to guide a loading cycle of the hauling machine.   
     
     
         16 . The controller of  claim 15 , wherein the loading sequence is programmed to identify a first target dump zone for a first payload delivered to the payload body and the first target dump zone is transmitted to the loading machine. 
     
     
         17 . The controller of  claim 16 , wherein the vision data module is configured to receive a continuous scanning data set including a placement of the first payload collected by the one or more visual sensors, and the loading sequence is programmed to incorporate the continuous scanning data set to identify one or more additional target dump zones for one or more additional loads delivered to the payload body and the one or more additional target dump zones are transmitted to the loading machine and continuously updates based on the continuous data set. 
     
     
         18 . The controller of  claim 17 , further comprising a pressure sensor monitoring module configured to receive a suspension pressure monitored and collected by one or more pressure sensors coupled to the hauling machine, wherein the loading sequence is programmed to incorporate the continuous scanning data set and the suspension pressure such that the one or more additional target dump zones are continuously updated to produce a balanced payload within the payload body. 
     
     
         19 . The controller of  claim 18 , further including a payload monitoring module configured to receive a load volume and a load density of a payload in a payload bucket of the loading machine, wherein the loading sequence is programmed to include the load volume and the load density to identify the one or more additional target dump zones. 
     
     
         20 . The controller of  claim 15 , wherein the loading sequence module generates an event log based on the loading sequence, the event log includes one or more events performed by the hauling machine and the loading machine, wherein the event log is analyzed to determine an amount of work performed by the hauling machine and the loading machine.