Abstract: A payload management system embodiment may include a force sensing system operatively associated with a bucket of an excavator. The force sensing system senses a magnitude of a force required to hold the bucket at a defined position with respect to a reference datum. An angle sensing system operatively associated with the bucket senses a direction of the force with respect the reference datum. A processing system operatively associated with the force system and the angle sensing system processes data relating to the magnitude of the force and the direction of the force to determine the amount of the payload in the bucket.

Abstract: A method of calibrating strain sensors operatively associated with a machine may involve the steps of: Calculating, for each of n loading conditions, at least one structural load associated with at least one member of the machine to produce n calculated structural loads corresponding to the n loading conditions; measuring, for each of n machine positions, at least one strain associated with the at least one member of the machine to produce n measured strains corresponding to the n loading conditions; and determining curve fit parameters from said n calculated structural loads and said n measured strains, the curve fit parameters relating measured strain and structural loads over n loading conditions.

Abstract: A payload management system embodiment may include a force sensing system operatively associated with a bucket of an excavator. The force sensing system senses a magnitude of a force required to hold the bucket at a defined position with respect to a reference datum. An angle sensing system operatively associated with the bucket senses a direction of the force with respect the reference datum. A processing system operatively associated with the force system and the angle sensing system processes data relating to the magnitude of the force and the direction of the force to determine the amount of the payload in the bucket.

Abstract: A method for calibrating strain transducers mounted to a power shovel may include the steps of: Calculating at least one member joint load for a known loading condition when at least one member of the power shovel is in a statically determinate configuration; determining a calculated shear force and a calculated normal force in the member of the power shovel based on the calculated member joint load; measuring a strain in the member; determining a measured shear force and a measured normal force for the member based on the measured strain; and determining a calibration constant from the calculated shear and normal forces and the measured shear and normal forces.

Abstract: A method of optimizing machine performance in a plurality of load cases. According to the present invention, a maximum load case, which involves application of a maximum force to at least one member of a machine, is determined for the machine. For each of a plurality of member joints of the machine, a maximum member joint load is determined for the maximum load case for the machine. The machine is then operated by applying a force to the at least one member of the machine in each of the plurality of load cases so as not to exceed the maximum member joint load while exceeding the maximum force during at least one of the plurality of load cases.

Abstract: A method of determining a load on at least one member of a power shovel may include the steps of: sensing a strain in a boom of the power shovel; determining a plurality of member joint loads based on strain sensed in the boom; and determining the load on the at least one member of the power shovel from the plurality of member joint loads.

Abstract: A method of calibrating strain sensors operatively associated with a machine may involve the steps of: Calculating, for each of n loading conditions, at least one structural load associated with at least one member of the machine to produce n calculated structural loads corresponding to the n loading conditions; measuring, for each of n machine positions, at least one strain associated with the at least one member of the machine to produce n measured strains corresponding to the n loading conditions; and determining curve fit parameters from said n calculated structural loads and said n measured strains, the curve fit parameters relating measured strain and structural loads over n loading conditions.

Abstract: A method of optimizing machine performance in a plurality of load cases. According to the present invention, a maximum load case, which involves application of a maximum force to at least one member of a machine, is determined for the machine. For each of a plurality of member joints of the machine, a maximum member joint load is determined for the maximum load case for the machine. The machine is then operated by applying a force to the at least one member of the machine in each of the plurality of load cases so as not to exceed the maximum member joint load while exceeding the maximum force during at least one of the plurality of load cases.

Abstract: A method of determining a load on at least one member of a power shovel may include the steps of: sensing a strain in a boom of the power shovel; determining a plurality of member joint loads based on strain sensed in the boom; and determining the load on the at least one member of the power shovel from the plurality of member joint loads.

Abstract: A method for calibrating strain transducers mounted to a power shovel may include the steps of: Calculating at least one member joint load for a known loading condition when at least one member of the power shovel is in a statically determinate configuration; determining a calculated shear force and a calculated normal force in the member of the power shovel based on the calculated member joint load; measuring a strain in the member; determining a measured shear force and a measured normal force for the member based on the measured strain; and determining a calibration constant from the calculated shear and normal forces and the measured shear and normal forces.

Abstract: A method of optimizing machine performance in a plurality of load cases may involve the steps of: Determining a maximum load case for the machine, the maximum load case involving the application of a maximum force to at least one member of the machine; determining, for each of a plurality of member joints of the machine, a maximum member joint load for the maximum load case for the machine; and operating the machine by applying a force to the at least one member of the machine in each of the plurality of load cases so as not to exceed the maximum member joint load, the applied force exceeding the maximum force during at least one of the plurality of load cases.

Abstract: A method of optimizing machine performance in a plurality of load cases may involve the steps of: Determining a maximum load case for the machine, the maximum load case involving the application of a maximum force to at least one member of the machine; determining, for each of a plurality of member joints of the machine, a maximum member joint load for the maximum load case for the machine; and operating the machine by applying a force to the at least one member of the machine in each of the plurality of load cases so as not to exceed the maximum member joint load, the applied force exceeding the maximum force during at least one of the plurality of load cases.

Abstract: A payload management system embodiment may include a force sensing system operatively associated with a bucket of an excavator. The force sensing system senses a magnitude of a force required to hold the bucket at a defined position with respect to a reference datum. An angle sensing system operatively associated with the bucket senses a direction of the force with respect the reference datum. A processing system operatively associated with the force system and the angle sensing system processes data relating to the magnitude of the force and the direction of the force to determine the amount of the payload in the bucket.

Abstract: A digging machine. The machine includes a rod having a central bore with at least two strain gauges angled relative to each other, a hoist rope, and a CPU configured to create a calibration table of a plurality of outputs from each of the two strain gauges, given various rope tensions and rope angles, determine an unknown rope tension and rope angle, use the output from one strain gauge and create a first set of data point angle and tension pairs from plurality of calibration outputs that correspond to the one output from one strain gauge, use the output from the other strain gauge and create a second set of data point angle and tension pairs from the plurality of calibration outputs that correspond to the one output from other strain gauge, and determine, based on where said two sets of data points intersect, rope tension and rope angle.

Abstract: A digging machine. The machine includes a rod having a central bore with at least two strain gauges angled relative to each other, a hoist rope, and a CPU configured to create a calibration table of a plurality of outputs from each of the two strain gauges, given various rope tensions and rope angles, determine an unknown rope tension and rope angle, use the output from one strain gauge and create a first set of data point angle and tension pairs from plurality of calibration outputs that correspond to the one output from one strain gauge, use the output from the other strain gauge and create a second set of data point angle and tension pairs from the plurality of calibration outputs that correspond to the one output from other strain gauge, and determine, based on where said two sets of data points intersect, rope tension and rope angle.

Abstract: A machine for raising and lowering a load, the machine including a platform, a boom attached at one end to the platform, a rod mounted transverse to the longitudinal axis of the boom on the other end of a boom, the rod having a central bore there through, with at least two strain gauges mounted therein and angled relative to each other, a hoist rope extending over the rod and having an end adapted to be attached to the load, and a mechanism connected to the at least two strain gauges for determining the angle of departure of the hoist rope from the rod and the amount of pull of the load on the hoist rope.

Abstract: A machine for raising and lowering a load, the machine including a platform, a boom attached at one end to the platform, a rod mounted transverse to the longitudinal axis of the boom on the other end of a boom, the rod having a central bore there through, with at least two strain gauges mounted therein and angled relative to each other, a hoist rope extending over the rod and having an end adapted to be attached to the load, and a mechanism connected to the at least two strain gauges for determining the angle of departure of the hoist rope from the rod and the amount of pull of the load on the hoist rope.

Abstract: A machine for raising and lowering a load, the machine including a platform, a boom attached at one end to the platform, a rod mounted transverse to the longitudinal axis of the boom on the other end of a boom, the rod having a central bore there through, with at least two strain gauges mounted therein and angled relative to each other, a hoist rope extending over the rod and having an end adapted to be attached to the load, and a mechanism connected to the at least two strain gauges for determining the angle of departure of the hoist rope from the rod and the amount of pull of the load on the hoist rope.

Abstract: A machine for raising and lowering a load, the machine including a platform, a boom attached at one end to the platform, a rod mounted transverse to the longitudinal axis of the boom on the other end of a boom, the rod having a central bore there through, with at least two strain gauges mounted therein and angled relative to each other, a hoist rope extending over the rod and having an end adapted to be attached to the load, and a mechanism connected to the at least two strain gauges for determining the angle of departure of the hoist rope from the rod and the amount of pull of the load on the hoist rope.

Abstract: A machine for raising and lowering a load, the machine including a platform, a boom attached at one end to the platform, a rod mounted transverse to the longitudinal axis of the boom on the other end of a boom, the rod having a central bore there through, with at least two strain gauges mounted therein and angled relative to each other, a hoist rope extending over the rod and having an end adapted to be attached to the load, and a mechanism connected to the at least two strain gauges for determining the angle of departure of the hoist rope from the rod and the amount of pull of the load on the hoist rope.