Collision Avoidance Control Method and System

Abstract

A control method and system for avoiding collisions between components of a machine includes a controller that receives position signals from sensors associated with movable components of the machine. The controller determines the positional coordinate representations of the components within a coordinate system based upon the position signals and the outer dimensions of the respective components. If any of the components are within preset collision slowdown or shutdown zones within the coordinate system, then the speed of those components is restricted or the components are shutdown, respectively, in the direction of collision.

1 . A machine for removal of material from a surface, the machine comprising:
 an undercarriage having a front end and a rear end;   a plurality of propulsive drive mechanisms, the undercarriage being supported on the plurality of propulsive drive mechanisms to position the machine proximate to the surface;   a cutter head;   a tool support and positioning assembly supported on the undercarriage, the tool support and positioning assembly being moveable relative to the undercarriage, the cutter head being disposed on the tool support and positioning assembly and moveable relative to the undercarriage at a speed;   at least one support position sensor associated with the tool support and positioning assembly, the at least one support position sensor being adapted to dynamically determine a position of the tool support and positioning assembly;   a gathering head coupled to the undercarriage, the gathering head being disposed at the front end of the undercarriage; and   a controller configured to:
 receive a tool support position signal from the at least one support position sensor, 
 determine respective positional coordinate representations of the gathering head, the tool support and positioning assembly, and the cutter head within a coordinate system, 
 determine if any of the gathering head, the tool support and positioning assembly, and the cutter head are within a preset collision slowdown zone within the coordinate system based on the respective positional coordinate representations, 
 determine if any of the gathering head, the tool support and positioning assembly, and the cutter head are within a preset collision shutdown zone within the coordinate system based on the respective positional coordinate representations, 
 if any of the gathering head, the tool support and positioning assembly, and the cutter head is within said preset collision slowdown zone, then restrict the speed of the gathering head, the tool support and positioning assembly, and the cutter head in a direction of collision within said preset collision slowdown zone to a reduced speed within said preset collision slowdown zone, 
 if any of the gathering head, the tool support and positioning assembly, and the cutter head is within said preset collision shutdown zone, then stop movement of the gathering head, the tool support and positioning assembly, and the cutter head in the direction of collision within the preset collision shutdown zone, and 
 if none of the gathering head, the tool support and positioning assembly, and the cutter head is within at least one of the preset collision slowdown zone and the preset collision shutdown zone, then permit full speed movement of the tool support and positioning assembly. 
   
     
     
         2 . The machine of  claim 1  wherein the controller includes an automatic operation, wherein the controller is configured to restrict the speed movement of the tool support and positioning assembly in a direction other than the direction of collision when any of the gathering head, the tool support and positioning assembly, and the cutter head is within said preset collision slowdown zone. 
     
     
         3 . The machine of  claim 1  wherein the controller includes a manual operation, wherein the controller is configured to permit full speed movement of the tool support and positioning assembly in directions other than the direction of collision when any of the gathering head, the tool support and positioning assembly, and the cutter head is within said preset collision slowdown zone. 
     
     
         4 . The machine of  claim 1  wherein the coordinate system is a Cartesian coordinate system. 
     
     
         5 . The machine of  claim 1  wherein the tool support and positioning assembly includes at least two of a longitudinally movable boom infeed extension, a rollover joint, and a cantilevered lift arm. 
     
     
         6 . The machine of  claim 1  further including at least one hydraulic cylinder associated with the movement of the tool support and positioning assembly, and wherein the at least one support position sensor is associated with the at least one hydraulic cylinder. 
     
     
         7 . The machine of  claim 1  wherein the controller is configured to determine positional coordinate representations of a protective envelope above the gathering head in determining the positional coordinate representations of the gathering head. 
     
     
         8 . The machine of  claim 1  further including at least one moveable stabilizer associated with an underside of the gathering head, and at least one stabilizer position sensor associated with the at least one stabilizer, wherein the controller is further configured to
 receive a stabilizer position signal from the at least one stabilizer position sensor, 
 determine respective positional coordinate representations of the gathering head and the at least one stabilizer within the coordinate system, 
 determine if any of the gathering head and the at least one stabilizer are within a second preset collision slowdown zone based upon the respective positional coordinate representations of the gathering head and the at least one stabilizer within the coordinate system, 
 determine if any of the gathering head and the at least one stabilizer are within a second preset collision shutdown zone based upon the respective positional coordinate representations of the gathering head and the at least one stabilizer within the coordinate system, 
 if any of the gathering head and the at least one stabilizer is within said second preset collision slowdown zone, then restrict the speed of the gathering head and the at least one stabilizer in a direction of collision within said second preset collision slowdown zone to a reduced speed within said second preset collision slowdown zone, 
 if any of the gathering head and the at least one stabilizer is within said second preset collision shutdown zone, then stop movement of the at least one stabilizer in the direction of collision within the second preset collision shutdown zone, and 
 if none of the gathering head and the at least one stabilizer is within at least one of the second preset collision slowdown zone and the second preset collision shutdown zone, then permit full speed movement of the stabilizer. 
 
     
     
         9 . The machine of  claim 8  including at least two stabilizers associated with the underside of the gathering head and at least two stabilizer position sensors, the controller being configured to received stabilizer position signals from the at least two stabilizer position sensors. 
     
     
         10 . A method of avoiding collisions between components of a machine having a gathering head, a cutter head, and a movable tool support and positioning assembly, the tool support and positioning assembly being moveable relative to the gathering head, the cutter head being disposed on the tool support and positioning assembly and moveable relative to the gathering head at a speed, the method comprising:
 receiving at least one tool support position signal from at least one support position sensor,   determining respective positional coordinate representations of the gathering head, the tool support and positioning assembly, and the cutter head within a coordinate system,   determining at least one of:
 if any of the gathering head, the tool support and positioning assembly, and the cutter head are within a preset collision slowdown zone within the coordinate system based upon the respective positional coordinate representations, and 
 if any of the gathering head, the tool support and positioning assembly, and the cutter head are within a preset collision shutdown zone within the coordinate system based upon the respective positional coordinate representations, 
   if any of the gathering head, the tool support and positioning assembly, and the cutter head is within said preset collision slowdown zone, then restricting the speed of the gathering head, the tool support and positioning assembly, and the cutter head in a direction of collision within said preset collision slowdown zone to a reduced speed within said preset collision slowdown zone,   if any of the gathering head, the tool support and positioning assembly, and the cutter head is within said preset collision shutdown zone, then stopping movement of the tool support and positioning assembly in the direction of collision within the preset collision shutdown zone, and   if none of the gathering head, the tool support and positioning assembly, and the cutter head is within at least one of the preset collision slowdown zone and the preset collision shutdown zone, then permitting full speed movement of the tool support and positioning assembly.   
     
     
         11 . The method of  claim 10  wherein the machine is automatically operable, and the method further includes restricting the speed movement of the tool support and positioning assembly in a direction other than the direction of collision when any of the gathering head, the tool support and positioning assembly, and the cutter head is within said preset collision slowdown zone. 
     
     
         12 . The method of  claim 10  wherein the machine is manually operable, and the method further includes permitting full speed movement of the tool support and positioning assembly in directions other than the direction of collision when any of the gathering head, the tool support and positioning assembly, and the cutter head is within said preset collision slowdown zone. 
     
     
         13 . The method of  claim 10  wherein the coordinate system is a Cartesian coordinate system. 
     
     
         14 . The method of  claim 10  wherein the step of receiving a tool support position signal includes receiving signals from at least two of a boom sensor, a swing sensor, a lift sensor, and a rollover joint sensor. 
     
     
         15 . The method of  claim 10  wherein the step of determining positional coordinate representations of the gathering head includes establishing positional coordinate representations of a protective envelope above the gathering head. 
     
     
         16 . The method of  claim 10  wherein the machine further includes at least one moveable stabilizer associated with an underside of the gathering head, and at least one stabilizer position sensor associated with the at least one stabilizer, and wherein the method further includes
 receiving a stabilizer position signal from the at least one stabilizer position sensor, 
 determining respective positional coordinate representations of the gathering head and the at least one stabilizer within the coordinate system, 
 determining if any of the gathering head and the at least one stabilizer are within a second preset collision slowdown zone within the coordinate system based upon the respective positional coordinate representations of the gathering head and the at least one stabilizer within the coordinate system, 
 determining if any of the gathering head and the at least one stabilizer are within a second preset collision shutdown zone within the coordinate system based upon the respective positional coordinate representations of the gathering head and the at least one stabilizer within the coordinate system, 
 if any of the gathering head and the at least one stabilizer is within said second preset collision slowdown zone, then restricting the speed of the gathering head and the at least one stabilizer in a direction of collision within said second preset collision slowdown zone to a reduced speed within said second preset collision slowdown zone, 
 if any of the gathering head and the at least one stabilizer is within said second preset collision shutdown zone, then stopping movement of the at least one stabilizer in the direction of collision within the second preset collision shutdown zone, and 
 if none of the gathering head and the at least one stabilizer is within at least one of the second preset collision slowdown zone and the second preset collision shutdown zone, then permitting full speed movement of the stabilizer. 
 
     
     
         17 . The machine of  claim 17  wherein the step of receiving a stabilizer position signal includes receiving stabilizer position signals from at least two stabilizer position sensors associated with at least two stabilizers, respectively. 
     
     
         18 . A machine for underground milling of a milling wall, the machine comprising:
 an undercarriage having a front end and a rear end;   a cutter head;   a tool support and positioning assembly supported on the undercarriage;   a gathering head coupled to the undercarriage; and   a controller configured to:
 determine coordinates of the tool support and positioning assembly, and the cutter head within a coordinate system, 
 determine coordinates of the gathering head within the coordinate system, 
 determine at least one of:
 if any of the gathering head, the tool support and positioning assembly, and the cutter head are within a preset collision slowdown zone within the coordinate system, and 
 if any of the gathering head, the tool support and positioning assembly, and the cutter head are within a preset collision shutdown zone within the coordinate system, 
 
 if any of the gathering head, the tool support and positioning assembly, and the cutter head is within said preset collision slowdown zone, then restrict the speed of the gathering head, the tool support and positioning assembly, and the cutter head within said preset collision slowdown zone to a reduced speed in a direction of collision within said preset collision slowdown zone, 
 if any of the gathering head, the tool support and positioning assembly, and the cutter head is within said preset collision shutdown zone, then stop movement of the tool support and positioning assembly in the direction of collision within the preset collision shutdown zone, and 
 if none of the gathering head, the tool support and positioning assembly, and the cutter head is within at least one of the preset collision slowdown zone and the preset collision shutdown zone, then permit full speed movement of the tool support and positioning assembly. 
   
     
     
         19 . The machine of  claim 19  wherein the tool support and positioning assembly is moveable relative to the undercarriage, the cutter head being disposed on the tool support and positioning assembly and moveable at a speed relative to the undercarriage, the tool support and positioning assembly including a boom infeed extension and a cantilevered lift arm; the method further including at least one boom actuator associated with the boom infeed extension, at least one lift actuator associated with the cantilevered lift arm, a boom sensor associated with the at least one boom actuator, the boom sensor being adapted to dynamically determine a position of the at least one boom actuator, and a lift sensor associated with the at least one lift actuator, the lift sensor being adapted to dynamically determine a position of the at least one lift actuator; the gathering head having an upper surface, the controller being configured to receive a boom position signal from the boom sensor, and receive a lift position signal from the lift sensor. 
     
     
         20 . The machine of  claim 19  additionally including left and right stabilizers associated with an underside of the gathering head, and left and right stabilizer position sensors associated with the left and right stabilizers, respectively, wherein the controller is further configured to
 receive left and right stabilizer position signals from the left and right stabilizer position sensors, 
 determine respective Cartesian coordinates of the gathering head and the left and right stabilizers within the Cartesian coordinate system, 
 determine if any of the gathering head and either of the left and right stabilizers are within a second preset collision slowdown zone, 
 determine if any of the gathering head and either of the left and right stabilizers are within a second preset collision shutdown zone, 
 if any of the gathering head and either of the left and right stabilizers is within said second preset collision slowdown zone, then restrict the speed of at least one of the left and right stabilizers in a direction of collision within said second preset collision slowdown zone to a reduced speed within said second preset collision slowdown zone, 
 if any of the gathering head and either of the left and right stabilizers is within said second preset collision shutdown zone, then stop movement of at least one of the left and right stabilizers in the direction of collision within the second preset collision shutdown zone, and 
 if none of the gathering head and either of the left and right stabilizers is within at least one of the second preset collision slowdown zone and the second preset collision shutdown zone, then permit full speed movement of the left and right stabilizers.