Laser Scanner-based End-effector Tracking and Joint Variable Extraction for Heavy Machinery

A survey of mining accidents has revealed that over 30% of all truck loading accidents can be addressed by providing dipper positioning feedback to the shovel operator. In this paper, a novel approach is presented for estimating a mining shovel’s dipper pose to obtain its arm geometry in real-time utilizing a two-dimensional laser scanner. The low spatial resolution of laser scanners and the need for accurate initialization challenge the reliability and accuracy of most laser-scanner-based object tracking methods. This work addresses these issues by using the shovel dipper’s kinematics model and position history, in conjunction with the dipper geometrical model, to track the dipper in space. The proposed method uses a bootstrap particle filter with a distance transformation in order to perform a global search in the workspace. The particle filter’s result is then used as the initial pose for an Iterative Closest Point algorithm that increases the accuracy of the pose estimate. The proposed method can be applied to other laser scanner-based object tracking applications in outdoor environments. Experiments performed on a mining shovel demonstrate the reliability, accuracy, and computational efficiency of the proposed approach. Moreover, using a single proximal sensor can simplify mounting, reduce maintenance costs and machine down time, and enhance tracking reliability.