Vision-based detection and control of machinery

A method for altering an operational condition of a material-handling vehicle (MHV) including the steps of:

• providing the MHV at a first location;
• providing a system for altering an operational condition of the MHV, the system comprising:
• a computer system having a processor configured to analyze visual data using a machine learning (ML) engine;
• a vision system comprising at least one camera mounted to the MHV and configured to generate visual data by imaging an observed area proximate the MHV and to transmit the visual data to the computer system for analysis;
• and
• a controller configured to receive an operational set point for the MHV and to execute operational commands generated by the processor, where such commands modify the operational condition of the MHV when executed by the controller,
• wherein the computer system is configured to:
• receive the visual data transmitted from the vision system;
• analyze the visual data using the ML engine to determine if a current operational condition of the MHV is within a tolerance band of the operational set point;
• where the current operational condition of the MHV is outside of the tolerance band of the operational set point, to generate operational commands for modifying the operational condition that are calculated to bring the current operational condition of the MHV within the tolerance band of the operational set point,
• placing a material on the MHV;
• inputting the operational set point to the controller;
• moving the material, using the MHV, to a second location;
• using the vision system, imaging the observed area and generating visual data related to the observed area;
• transmitting the visual data to the computer system;
• analyzing said visual data with ML engine of the computer system;
• determining if the current operational condition of the MHV is outside of the tolerance band of the operational set point;
• if the current operational condition of the MHV is outside of the tolerance band of the operational set point, generating operational commands for bringing the current operational condition within the tolerance band of the operational set point;
• transmitting the operational commands to the controller;
• using the controller, modifying the operational condition of the MHV.

A system for positioning and operating a conveyor, the system comprising:

• the conveyor having a receiving end and a discharge end and being configured to convey an aggregate from the receiving end to the discharge end;
• a vision sensor configured to sense a discharge area, generate data related to the discharge area, and transmit said data;
• a processor configured to receive and analyze the data from the vision sensor and generate commands to modify an operational condition of the conveyor;
• and
• a controller operatively connected to the conveyor for receiving and executing the commands generated by the processor,
• wherein, based on the commands, the controller adjusts a physical location of the discharge end and a discharge speed of the conveyor;
• wherein the vision sensor is at least one of a standard camera, a stereoscopic camera, an infrared camera, or a time-of-flight sensors;
• wherein the vision system is mounted to the discharge end of the conveyor;
• wherein the processor utilizes a neural network to analyze said data;
• wherein the discharge area is a hopper configured to receive aggregate;
• and
• wherein the physical location of the discharge end is changeable in three directions.