diff --git a/README.md b/README.md index 49105b5..a1ba2a5 100644 --- a/README.md +++ b/README.md @@ -20,7 +20,7 @@ Initiated and maintained by **[DigitalTwin Technology GmbH](https://www.digitalt | Site | 128 m terrain with pad, haul road, stockpile and a 2.5 m excavation pit; 40+ physics props from NVIDIA SimReady (CC BY 4.0) with checked masses and colliders | | Real machines (open-licensed) | Hitachi ZX200 excavator, IHI (Kato) IC120 crawler carrier, Komatsu D37PXi dozer (articulated, from the PWRI OPERA project, Apache-2.0); 35 m tower crane, cones, barrels and jersey barriers (Gazebo, CC0) | | Soil | The pit filled with 2 m of MPM soil (Newton implicit MPM) on the GPU, two-way coupled to the machine, in four presets switchable live: dry sand, moist sand, loam and clay. Cohesion is checked against vertical-cut stability and McKyes cutting forces, and dug clods break up to their remoulded strength; only soil near the bucket is particles, resting soil elsewhere is a heightfield, and cut faces slump to the angle of repose. The sand steps at 30 Hz and the machine at 60 Hz; the dig cycle runs at 1.3× real time, and a trench dug in one lane (1.2×) reaches 1.7 m with 43–45° sides | -| Excavator | The real Hitachi ZX200 (OPERA URDF geometry and joint limits, curved bucket with teeth) driven by its real hydraulic cylinders (Hitachi bores, 34.3 MPa main relief and port reliefs, pump flow shared between functions, bucket four-bar linkage) and swing motor (13.3 min⁻¹, 68.9 kN·m, braking on its cross-over reliefs), so force and speed vary with pose and the machine slows and stalls under load. Digging force at the teeth 149 kN against 151–158 kN published. Full dig–swing–load cycle into a dump truck, lifting while swinging like an operator: 15–18 s and about 1 t per pass | +| Excavator | The real Hitachi ZX200 (OPERA URDF geometry and joint limits, curved bucket with teeth) driven by its real hydraulic cylinders (Hitachi bores, 34.3 MPa main relief and port reliefs, pump flow shared between functions, bucket four-bar linkage) and swing motor (braking on its cross-over reliefs, with friction), so force and speed vary with pose and the machine slows and stalls under load. Joint speeds per direction, swing speed (11.2 min⁻¹ at 1800 min⁻¹ eco) and swing friction are calibrated against PWRI's step tests on a real ZX200 (ISARC 2025); the swing torque (77.9 kN·m) and the bucket's angle offset are provisional ([phase2/RESULTS.md](phase2/RESULTS.md)). Digging force at the teeth 149 kN against 151–158 kN published. Full dig–swing–load cycle into a dump truck, lifting while swinging like an operator: 16–19 s per pass in a trench, about 20–21 s and 0.7–1.3 t per pass loading the carrier (clay lowest) | | Haul cycle | An IHI IC120 crawler carrier (PWRI OPERA model) is loaded by the excavator, drives the load to a spoil area, tips it out as MPM soil and comes back. The operator model sends it off when full, waits while it is away, and spreads passes along the vessel; sticky loads are shaken out. One excavator and one carrier deliver 124–181 t/h depending on soil, with the excavator waiting 16–26 % of the time. With two carriers (`--carriers 2`), they take turns at the excavator, a waiting place and gates keep them apart on the one-lane road, and loading goes up 12–27 % over 10 minutes. Over 25 minutes the gain holds at 19 % while the excavator has soil within reach ([phase2/RESULTS.md](phase2/RESULTS.md)) | | Spoil spreading | A Komatsu D37PXi dozer (PWRI OPERA model) spreads each dumped load in lanes fanned out from the dump heap and builds the fill layer by layer (0.3 m lifts), its blade pushing MPM soil under grade and load control as on the real machine; the tracks slip above traction. It works while the carrier is away and parks before it comes back, so the carrier never waits; mean blade forces of 5–28 kN per pass match the sliding-load estimate ([phase2/RESULTS.md](phase2/RESULTS.md)) | | Browser client | Levers and keyboard control, cylinder pressure gauges, stall warnings, live truck load, the carrier, the dozer and the spoil area, a "Send carrier" button; 60 fps | diff --git a/phase2/RESULTS.md b/phase2/RESULTS.md index 21223a9..07d446f 100644 --- a/phase2/RESULTS.md +++ b/phase2/RESULTS.md @@ -1242,7 +1242,7 @@ Part 4 put the late slowdown down to the pit being dug out. That was wrong: at t **The fix:** before each pass the operator looks at the pit and chooses where to cut (`_plan_face`). - **The choice:** seven swing directions (+20° to −40°, negative toward the truck side) along the standard dig path (cutting edge 4.4–7.4 m from the swing axis), each a bucket-width strip. - **The score:** the soil the cut can take. The cut goes 0.42 m into the strip but stays 0.08 m above the highest hard floor under it, which matters on the sloped sides. -- **Learning from poor passes:** a strip whose pass brings back less than 30 % of a full bucket is set aside for 12 passes. +- **Learning from poor passes:** a strip whose pass brings back less than 30 % of a full bucket is set aside for 12 passes. (Since the PWRI calibration, also, in clay, one that carries less than half a bucket to the carrier; set-aside strips come back when no other has a cut worth taking.) - **Finishing:** when no strip's cut holds 0.3 m³, the excavation is finished within reach. The operator stops and sends the carrier off. **What did not work, found with per-pass logs:** @@ -1397,3 +1397,137 @@ With bulking in, the autopilot's bucket came up only 65–70 % full by volume in - **Loam runs heavy:** its lumps compact in the bucket, and it overshoots the preset target (1.24 t) by about 18 %. - **Delivered tonnes are not comparable with earlier runs:** they now follow from realistic loose volumes, so loose soil fills the carrier sooner (clay: 10–12 passes per load instead of 9–10 before bulking). + +## Calibration against PWRI's ZX200 step tests + +PWRI (the OPERA team) recorded single-joint velocity steps on a real ZX200 under its automation controller: free air, empty bucket, 1800 min⁻¹, eco mode. The model parameters below were identified from those measurements (Abe, Matsusaka, Endo, Yamauchi, Hashimoto, "Dynamics Model of an Excavator in an Open Source Physical Simulator for Developing Autonomous Construction", ISARC 2025, [doi:10.22260/ISARC2025/0054](https://doi.org/10.22260/ISARC2025/0054)). The recordings themselves are PWRI's and are not published here. + +The joint angles and speeds are the reliable part of the recordings. The pressure channels are not verified yet, so the parameters that rest on them are marked provisional. + +**Method.** The simulator ran each recorded step from the same start pose, in free air. A full-command step is full lever; a ±0.3 rad/s step opens the lever to the share of the model's speed at that pose. Each joint and direction was compared on steady speed, delay to 10 % of it, and for the swing, acceleration, braking, the time to 90° and the stopping angle. + +**What changed** (`hydraulics.py`, `excavator_server.py`): + +| | Before | Now | Source | +|---|---|---|---| +| Swing speed at full lever | 1.39 rad/s (13.3 min⁻¹ spec, full power) | 1.17 rad/s | joint speed | +| Swing relief | 30.4 MPa (brochure) | 34.3 MPa, so 77.9 kN·m at 2.27 L/rad | peak motor pressure, accelerating and braking (**provisional**) | +| Swing friction | none | 16 kN·m (Coulomb) | the house speeds up more slowly than it brakes | +| House inertia about the swing axis | about 60 t·m² in total, boom raised and arm in (mesh shells) | about 112 t·m² (house Izz +52.8 t·m²) | acceleration and braking at that torque (**provisional**, scales with the relief) | +| Boom flow, raise / lower | 388 / 388 L/min | 375 / 270 L/min | joint speed per direction | +| Arm flow, crowd / out | 388 / 388 L/min | 495 / 265 L/min (crowd regenerates rod oil, so it exceeds the pumps) | joint speed per direction | +| Bucket flow, curl / dump | 194 / 194 L/min | 332 / 315 L/min | joint speed per direction, with PWRI's bucket angle read as ours + 0.622 rad (**provisional**, see below) | +| Moment-arm floor for speed commands | a hard 5 cm floor: joint speed jumps where dL/dq crosses it | eases onto 5 cm, (J⁴ + J_min⁴)^¼: no kink, within 1.5 % of J above 10 cm | boom and bucket near their stroke ends | +| Command response | none | optional: dead time 0.30 s swing (+0.30 s from rest), 0.42 / 0.62 s boom up / down, 0.55 / 0.45 s arm crowd / out, 0.33 s bucket; 0.15 s lag | delay to 10 % speed | +| Port relief | 39.2 MPa | unchanged | the boom's head side spikes to the 41 MPa sensor limit for about 0.05 s when a lowering boom stops: overshoot, not a setting | + +The auto operator plans swing stops with friction included: the house brakes at (relief torque + friction) / inertia. It measures the inertia online from relief torque less friction while speeding up. + +The command response is off by default (`ExcavatorSim(command_response=True)`, `ros_server.py --command-response`). The dead time is mostly PWRI's controller and the pilot circuit, so it belongs with velocity commands, not with the browser's levers. + +**Result.** The simulator ran PWRI's steps with the command response on (`command_response=True`), and its response was compared with what was measured: + +| Full-command step | Speed, model now | Speed, before | Delay to 10 %, now (before: about 0) | +|---|---|---|---| +| Swing | 1.17 rad/s, within 0.5 % | +19 % | within 0.05 s | +| Boom up | within 1 % | +13 % | within 0.04 s | +| Boom down | within 4 % | +43 % | within 0.03 s | +| Arm crowd | within 1 % | −17 % | within 0.03 s | +| Arm out | within 1 % | +46 % | within 0.03 s | +| Bucket curl / dump | within 1 % / within 1 % (**provisional** angle reading) | −31 % / −6 % (angle read as ours, 194 L/min) | within 0.03 s | + +Swing details, model now against measured: acceleration within 4 %, braking within 3 %, 90° from the command 0.13 s sooner, stopping angle 4° longer. Before, the house accelerated twice as hard, braked 1.4 times as hard, and reached 90° 1.4 s sooner. + +**The bucket: its angle and its moment arm (provisional).** In PWRI's ±0.3 rad/s bucket steps the pilot pressure stays constant over the whole sweep, so the valve opening and the flow are fixed. The bucket's speed then changes with angle only through the four-bar's moment arm dL/dq, and curl and dump give the same curve. With PWRI's bucket angle read as our URDF angle, the model can't follow that curve. Toward curl the machine's moment arm falls to 46 % of its peak at 1.92 rad; the model's falls to 8 %, close to toggle. + +- **Read as ours + 0.622 rad,** the model's own geometry follows the curve to about 10 % rms over 0.1–1.9 rad. Fitting the offset to the curve alone gives 0.585–0.625 rad. The lowest bucket angle in every PWRI run (0.007) then falls on the URDF's dump limit (−0.622). +- **Moving pins instead** would put the bucket's link pin 0.31 m off its boss in the mesh, and the digging force would drop to about 120 kN against the published 151–158 kN. + +So the geometry stays, and the comparison reads PWRI's bucket angle as ours + 0.622 rad (`hydraulics.PWRI_BUCKET_OFFSET`). PWRI hasn't confirmed this convention yet. One check disagrees: in free air the bucket cylinder's force (from the unverified pressure channels) changes sign at about 1.15 rad of PWRI's angle, while the URDF bucket's centre of mass passes under its pin at 0.98 rad of ours (1.6 rad of theirs). The URDF masses aren't verified either. + +With that reading, the bucket takes 332 L/min to curl and 315 L/min to dump. Both are well above PWRI's bucket flow channels (about 230 and 215 L/min, indicative), so through the measured range the model's moment arm may be about a quarter too long. Full-command steps against the machine: + +| | Curl | Dump | +|---|---|---| +| Speed over the last 40 % of the step | −0.6 % | +0.6 % | +| Peak speed | +6 % | +18 % | +| Travel during the step | −2 % | +15 % | +| Delay to 10 % | within 0.03 s | within 0.03 s | + +The model's dump reaches speed sooner than the machine's and peaks higher, so it travels further in the 1.2 s step. The ±0.3 rad/s bucket steps aren't compared: there the real controller holds the speed, which the open-loop lever can't reproduce. Boom, arm and swing came out as before. The house inertia in the swing test changed by about 2 % because the bucket now starts more open. + +Benchmarks after the bucket change (default settings), against the "Now" column below: +- Trench (`bench_trench.py 8`), passes 1–6: 15.7–22.2 s, mean 17.7 s, unchanged. Pass 5 timed out one stage. +- 130 s cycle (`bench_zone.py 130`): 7 passes, 7.6 t (7.8 t before), within the spread between runs. +- `test_env.py` passes. +- 1500 s haul benches (one carrier; before → now): dry sand 20.6 → 20.3 s per pass, 1.27 → 1.55 t per pass, 149 → 168 t/h loaded; + loam 20.3 → 19.7 s, 1.28 → 1.50 t, 163 → 166 t/h; clay 21.1 → 20.5 s, 0.81 → 0.69 t, 119 → 104 t/h. Stages skipped 7/10/12 → 13/5/13. + Cycles are slightly faster everywhere; the faster curl fills sand and loam better but clay worse, and the skip counts move both + ways, so these single runs show the trend, not a settled figure. Logs: `logs/haul_bench_pwri_bucket_long__1carrier.json`. + +**Benchmarks** (default settings: the command response off): + +| | Before | Now | +|---|---|---| +| Trench (`bench_trench.py 8`), passes 1–6 | 15.4–17.9 s per pass (mean 16.4) | 16.0–19.2 s (mean 17.7) | +| 130 s cycle (`bench_zone.py 130`) | 7–8 passes, 8.7–9.2 t (two runs) | 7 passes, 7.8 t | +| 1500 s haul, s per pass: dry sand / loam / clay | 19.8 / 19.5 / 19.6 | 20.6 / 20.3 / 21.1 | +| 1500 s haul, per pass into the carrier | 1.30 / 1.49 / 0.93 t | 1.27 / 1.28 / **0.81** t | +| 1500 s haul, loaded | 161 / 168 / 141 t/h | 149 / 163 / **119** t/h | +| 1500 s haul, stages skipped | 16 / 12 / 17 | 7 / 10 / 12 | + +Haul logs: `logs/haul_bench_fill_long__1carrier.json` (before) and `logs/haul_bench_pwri_soil_long__1carrier.json` (now, with the face planner change below). `logs/haul_bench_pwri_long__1carrier.json` is the new hydraulics with the old planner. + +- **Passes take about 1 s longer** (5 %): the swing is slower and gentler, as on the machine. +- **Fewer stages time out** in every soil. +- **Clay passes come up light:** 0.81 t against the handbooks' 0.92–1.04 t and 0.93 t before. Loam moved from 5 % over its range to inside it (1.0–1.4 t). +- **Clay and the face planner.** With the new hydraulics and the old planner, clay fell to 0.71 t a pass and one load took 25 passes. Per-pass traces showed no steady difference in what the bucket held at the start of the swing. The planner kept choosing one strip whose cut took slabs the bucket lost on the way out, at about 0.43 t a pass for some 30 passes. It brought back more than 30 % of a bucket at the start of the swing, so the planner never set it aside. Now, in clay, a pass that carries less than half a bucket to the carrier also sets its strip aside (`POOR_CARRIED`), and in every soil, strips set aside are taken again only when no other strip has a cut worth taking. That brought clay to 0.81 t and the longest load to 16 passes. The half-bucket rule hurt dry sand (1.11 t a pass): what spills on the swing there is no sign of a poor strip, so it applies to clay only. The remaining gap in clay is open. + +**The approach aimed at the previous strip.** Most thin clay passes came from the strip 20° left: the planner expected 0.8–1.2 m³ there, but its first pass brought out 3–59 kg, with three stages timed out. Neither the cut depth nor the drag was the cause. The pass count goes up only when the approach is reached, so the segment into the approach was planned with the previous pass's strip. The house swung back toward the new strip, turned to the old one for the approach, and then swung across to the new one again while penetrating. From −10° to +20° that is 37° of swing during the cut. The calibrated swing brakes at 0.82 rad/s², so it overshot to +27°, and the bucket stuck on the pit wall. A second pass in the same strip had no swing to make, which is why that strip dug well when chosen again. 'Swing back' and the approach now both aim for the next pass's strip (`_lane_pass`). The traced pass now carries 1.06 t with no stage skipped, and every pass that changes strip skips the detour. + +`bench_haul.py` now logs every pass (`pass_log`: strip, most held while digging, at the swing, carried, left after the dump) and stops after `PASSES=N` passes for a quick check. + +**Two other changes, tried and reverted.** Two other changes were tried for clay: + +- **The tear rule.** A curl that lost more than a quarter of the load would not be learned from (`CURL_TEAR`). One curl losing 842 of 882 kg had pulled the learned curl gain down to 18 kg. +- **Setting a poor strip aside at the carrier** (`_rest_if_poor`) instead of at the next approach. + +Both were tested with the approach fix in place: 3 runs of 25 passes per variant. The figures are mean kg dumped per pass, with each run in brackets: + +| | Neither change | Both changes | Set-aside change only | +|---|---|---|---| +| Clay | **1041** (1071, 1085, 968) | 940 (1009, 844, 967) | 985 (1037, 969, 949) | +| Loam | 1165 (1186, 1142, 1166) | 1093 (1103, 1112, 1063) | **1188** (1166, 1227, 1172) | +| Dry sand | 1326 (1331, 1323, 1325) | 1331 (1338, 1313, 1342) | n/a: neither change acts in sand | + +- **The tear rule lowered both cohesive soils:** clay 5 % and loam 8 % below the set-aside change alone. So limiting it to clay would not help either. +- **The learned gain no longer collapses:** it ended at 136–273 kg in the 9 clay runs. +- **The set-aside change made no difference** in 25 passes, nor over 1500 s of clay. That is where the deep pit gives repeated thin passes from one strip: 55.5 and 53.0 t loaded with the change, against 52.3 and 58.4 t without it. + +Both are reverted. + +**The approach fix alone**, against the same autopilot without it: + +- **25 passes:** clay and loam dump about 11 % more per pass (clay 935 → 1041 kg, mean of 4 old runs; loam 1047 → 1165 kg, 3 old runs), and passes are 1.5–2 s shorter. +- **1500 s, clay (one carrier):** 43.5 → 52.3 and 58.4 t loaded, 0.65 → 0.73 and 0.85 t per pass (`loaded_t` over all passes), 104 → 125 and 140 t/h loaded. Stages skipped fell from 13 to 3 and 8. +- **1500 s, dry sand:** no change beyond the spread: 70.0 and 62.2 t loaded before, 61.3 and 70.3 t after. +- **1500 s, loam:** no change beyond the spread either: 69.2 and 70.0 t before, 63.8 and 69.4 t after. Every loam run dug out all the soil within reach before 1500 s. +- **Other benches:** the trench (passes 1–6: 15.6–18.2 s) and the 130 s zone cycle (7 passes, 10.4 t) don't change strip between passes. `test_env.py` passes. + +**Still open:** + +- **Clay still has thin passes once the pit is deep:** 17–26 of about 70 passes in the 1500 s runs. These passes barely fill while digging (160–600 kg at most), unlike the early failures, which filled and then lost the load. Half of them are in the strip 20° left. +- **Dry sand stalls when a load is full.** When the last pass fills the carrier, the house sometimes stays over it, and the next 6 stages time out, losing about 30 s. This happened once to four times per 1500 s, with or without the fix, and sets most of dry sand's run-to-run spread. + +Logs: + +- 25-pass runs: `logs/haul_quick25_lane___.json`; the earlier checks are `logs/haul_quick25___1carrier.json`. +- 1500 s runs: `logs/haul_bench_lane_fix_long[2]__1carrier.json`, `logs/haul_bench_lane_old_long2__1carrier.json` and `logs/haul_bench_lane_restearly_long_clay_1carrier.json`. +- 1500 s runs before the bucket calibration: `logs/haul_bench_pwri_face_long__1carrier.json`, with the half-bucket rule in every soil; `logs/haul_bench_pwri_tear_long__1carrier.json`, with the tear guard; `logs/haul_bench_pwri_rest_long_clay_1carrier.json`, which adds the earlier set-aside. + +**Limits:** +- Every value is for 1800 min⁻¹ in eco mode. At full power the pumps deliver more: the spec swing speed is 19 % higher. +- The swing relief, and so the absolute inertia, depend on unverified pressure channels and on the 2.27 L/rad displacement derived from the spec sheet. The speeds and the ratio of torque to inertia come from joint data alone. +- The real swing's pressure falls as the house speeds up, while its acceleration stays nearly constant. The model accelerates at the relief torque. This doesn't affect the times above but would show in the pressures. +- Nothing here checks digging forces: the tests are in free air. +- The bucket flows rest on reading PWRI's bucket angle as ours + 0.622 rad, which PWRI hasn't confirmed. If the reading is wrong, the four-bar's geometry is wrong instead, and so is the bucket's digging force. diff --git a/phase2/bench_haul.py b/phase2/bench_haul.py index b420cb0..e9fe830 100644 --- a/phase2/bench_haul.py +++ b/phase2/bench_haul.py @@ -2,11 +2,17 @@ dumps it and comes back, for N simulated seconds. Reports what a site engineer would look at: loads, load mass, passes per load, loading time, the carrier's time away and its stages, the excavator's waiting time, and tonnes per hour delivered; the dozer's passes, blade forces and how flat it left the spread layer, and -how long the carrier waited for it; plus the real-time factor. +how long the carrier waited for it; plus the real-time factor. Each pass is logged too (`pass_log`): its strip, +the most the bucket held while digging, what it held at the swing, what it carried to the carrier and what it +left after the dump, so one run shows where a soil's loads go. + +A quick check stops after a number of passes instead (PASSES=25 is about 500 s): enough to compare two +versions of the autopilot pass by pass, in a quarter of the time. Progress goes to stderr every 100 s. ../phase0/.venv-newton/bin/python bench_haul.py 600 # dry sand SOIL=loam ../phase0/.venv-newton/bin/python bench_haul.py 600 SOIL=loam CARRIERS=2 ../phase0/.venv-newton/bin/python bench_haul.py 600 # two carriers sharing the road + SOIL=clay PASSES=25 ../phase0/.venv-newton/bin/python bench_haul.py 1500 # quick check: the first 25 passes """ import json @@ -21,6 +27,7 @@ secs = float(sys.argv[1]) if len(sys.argv) > 1 else 600.0 soil = os.environ.get("SOIL", ex.soils.DEFAULT_SOIL) n_carriers = int(os.environ.get("CARRIERS", "1")) +max_passes = int(os.environ.get("PASSES", "0")) or None sim = ex.ExcavatorSim(soil=soil, carriers=n_carriers) sim.auto = True fleet = sim.fleet @@ -28,8 +35,36 @@ t0 = time.perf_counter() prev = {c.index: c.stage for c in fleet} idle_spot = 0.0 -while sim.sim_time < secs: +pass_log, cur, prev_stage, next_report = [], None, None, 100.0 +DIG = ("penetrate", "drag", "drag-curl", "curl") +while sim.sim_time < secs and (max_passes is None or sim.passes < max_passes): sim.step() + if sim.stage_name != prev_stage: + st, fill = sim.stage_name, round(sim._bucket_fill()) + if st == "approach" and cur is not None: + pass_log.append(cur) + cur = None + if cur is None: + n = sim.passes + (st == "approach") # the count goes up as the approach ends + f = sim._faces.get(n) if sim.adaptive_face else None + cur = {"pass": n, "t": round(sim.sim_time, 1), "face": None if f is None else [f["psi"], f["shift"], round(f["avail_m3"], 2)], + "dig_max_kg": 0, "early_curl": False, "skips": len(sim.skipped)} + if prev_stage in DIG: + cur["dig_max_kg"] = max(cur["dig_max_kg"], fill) + if st == "curl" and prev_stage not in ("drag-curl", "curl"): + cur["early_curl"] = True # curled before the planned curl point (the load was there) + if st == "swing to truck": + cur["at_swing_kg"] = fill + elif st == "dump": + cur["carried_kg"] = fill + elif st == "swing back": + cur["left_kg"] = fill + prev_stage = st + if cur is not None and prev_stage in DIG: + cur["dig_max_kg"] = max(cur["dig_max_kg"], round(sim.auto_fill)) + if sim.sim_time >= next_report: + print(f"{sim.sim_time:.0f} s: {sim.passes} passes, {sum(x['load_kg'] for x in loads) / 1000:.1f} t in {len(loads)} loads", file=sys.stderr, flush=True) + next_report += 100.0 if fleet.at_spot is None: idle_spot += sim.frame_dt # no carrier at the loading spot for c in fleet: @@ -42,12 +77,19 @@ prev[c.index] = c.stage wall = time.perf_counter() - t0 sim.measure() +if cur is not None and "left_kg" in cur: + pass_log.append(cur) +for x, nxt in zip(pass_log, pass_log[1:] + [{"skips": len(sim.skipped)}]): + x["skips"] = nxt["skips"] - x["skips"] # stages skipped in this pass +secs = sim.sim_time # a quick check stops early +done = [x for x in pass_log if "carried_kg" in x] trips = fleet.trips delivered_t = fleet.delivered_kg / 1000.0 out = { "soil": soil, "carriers": n_carriers, - "sim_s": secs, + "sim_s": round(secs, 1), + "stopped_after_passes": max_passes, "realtime_factor": round(secs / wall, 3), "loads": loads, "trips": trips, @@ -74,6 +116,11 @@ "pit_left_t": round(float((sim.zones.count_np * sim._pit_cols).sum()) * sim.particle_mass / 1000, 1), "pit_done": sim.pit_done, "faces": [(f["psi"], f["shift"]) for f in sim.face_log], + "curl_gain_kg": round(sim.curl_gain), + "mean_carried_kg": round(float(np.mean([x["carried_kg"] for x in done]))) if done else None, + "mean_dumped_kg": round(float(np.mean([x["carried_kg"] - x["left_kg"] for x in done]))) if done else None, + "thin_passes": sum(1 for x in done if x["at_swing_kg"] < 0.5 * sim.full_kg), + "pass_log": pass_log, "dozer": {**{k: round(v, 2) for k, v in sim.dozer.counters.items()}, "mean_push_kN": sim.dozer.push_force}, "spread": sim.dozer.spread_report(sim._surface), } diff --git a/phase2/excavator_server.py b/phase2/excavator_server.py index d290b98..76c2e43 100644 --- a/phase2/excavator_server.py +++ b/phase2/excavator_server.py @@ -13,8 +13,10 @@ * relief valve - the torque is capped at relief pressure x piston area x moment arm, separately for pushing (head side) and pulling (rod side); the reference can't run further ahead than that torque can pull, so a joint that meets more resistance slows down - and stalls instead of pushing through. Swing is a joint-space motor with a fixed - torque limit. + and stalls instead of pushing through. Swing is a hydraulic motor: speed from its + flow, torque capped at the swing relief, with friction. + * response - optional (command_response=True): the levers reach the spools through the dead time + and lag PWRI measured on their ZX200 under velocity commands (hydraulics.py). The arm is a Newton articulation solved with MuJoCo; its bucket is a dynamic MPM collider, so the sand pushes back on the arm (two-way coupling as in Newton's mpm_twoway_coupling example). @@ -34,6 +36,7 @@ import argparse import asyncio +import collections import json import math import struct @@ -111,7 +114,12 @@ def _heaped_profile(): # from the area-weighted shells of the OPERA meshes, scaled to these masses (plate structures). MASS = {"house": 9800.0, "boom": 1450.0, "stick": 680.0, "bucket": 640.0} COM = {"house": (-0.48, 0.17, 0.79), "boom": (2.00, 0.01, 1.95), "stick": (0.34, -0.01, 0.73), "bucket": (0.29, -0.01, 0.72)} -INERTIA = {"house": (10518.0, 17319.0, 20667.0), "boom": (1028.0, 3635.0, 2661.0), "stick": (304.0, 673.0, 383.0), "bucket": (131.0, 159.0, 183.0)} +# The house's inertia about its vertical axis (and its pitch axis, as mass further out behind the swing axis +# adds to both) is raised by 52.8 t m2 over the mesh shells: the total about the swing axis then matches PWRI's +# ZX200 swing tests (about 112 t m2 with the boom raised, arm in, bucket empty, at the swing torque in +# hydraulics.py; ISARC 2025, doi:10.22260/ISARC2025/0054), where the mesh-based masses gave about 60. The +# counterweight sits further out than a uniform house shell puts it. +INERTIA = {"house": (10518.0, 70149.0, 73497.0), "boom": (1028.0, 3635.0, 2661.0), "stick": (304.0, 673.0, 383.0), "bucket": (131.0, 159.0, 183.0)} JOINTS = ["swing", "boom", "stick", "bucket"] LINKS = ["house", "boom", "stick", "bucket"] GLB_NODES = {"house": "body_link", "boom": "boom_link", "stick": "arm_link", "bucket": "bucket_link"} @@ -123,7 +131,7 @@ def _heaped_profile(): LEVER_SIGN = np.array([1.0, -1.0, -1.0, -1.0]) # swing: a joint-space actuator (swing motor); boom, stick and bucket are driven by their cylinders # (hydraulics.py), whose flow and relief set the joint speed and torque limits for each pose -SWING_VMAX, SWING_TAU = hyd.SWING_SPEED, hyd.SWING_TORQUE # 13.3 min^-1, 68.9 kN m (hydraulics.py) +SWING_VMAX, SWING_TAU, SWING_FRICTION = hyd.SWING_SPEED, hyd.SWING_TORQUE, hyd.SWING_FRICTION # 1.17 rad/s, 77.9 kN m, 16 kN m (hydraulics.py) KP = {"swing": 2.0e6, "boom": 3.0e7, "stick": 8.0e6, "bucket": 1.5e6} KD = {"swing": 8.0e5, "boom": 3.0e6, "stick": 6.0e5, "bucket": 4.0e4} @@ -354,6 +362,7 @@ def hydraulics_kernel( tau_hi: wp.array[float], q_lo: wp.array[float], q_hi: wp.array[float], + friction: wp.array[float], dt: float, joint_f: wp.array[float], torque: wp.array[float], @@ -373,7 +382,8 @@ def hydraulics_kernel( over = wp.max(q - q_hi[j], 0.0) - wp.max(q_lo[j] - q, 0.0) if over != 0.0: tau = tau - 10.0 * kp[j] * over - kd[j] * joint_qd[j] - joint_f[j] = tau + # Coulomb friction against the motion (smoothed over 0.02 rad/s); the actuator torque above doesn't include it + joint_f[j] = tau - friction[j] * wp.tanh(joint_qd[j] / 0.02) @wp.kernel @@ -527,9 +537,12 @@ class ExcavatorSim: ("swing back", 0, 6.0, 2.6 + DIG_Z, -95), # lowers while swinging, once clear of the truck ] - def __init__(self, voxel=0.08, ppc=2, soil=soils.DEFAULT_SOIL, iterations=None, fps=60.0, pool=POOL, mpm_every=MPM_EVERY, haul=True, dozer=True, carriers=1): + def __init__(self, voxel=0.08, ppc=2, soil=soils.DEFAULT_SOIL, iterations=None, fps=60.0, pool=POOL, mpm_every=MPM_EVERY, haul=True, dozer=True, carriers=1, command_response=False): wp.init() - self.kwargs = {"voxel": voxel, "ppc": ppc, "soil": soil, "iterations": iterations, "fps": fps, "pool": pool, "mpm_every": mpm_every, "carriers": carriers} + self.kwargs = {"voxel": voxel, "ppc": ppc, "soil": soil, "iterations": iterations, "fps": fps, "pool": pool, "mpm_every": mpm_every, "carriers": carriers, "command_response": command_response} + # levers reach the spools through the dead time and lag of PWRI's ZX200 under velocity commands + # (hydraulics.COMMAND_DEAD; off: the spools follow the levers at once, as before) + self.command_response = command_response self.soil = soil material = soils.SOILS[soil] density, friction = material["density"], material["friction"] @@ -736,6 +749,7 @@ def add_boxes(body, boxes, cfg): # actuator parameters on the GPU arr = lambda d: wp.array([float(d[j]) for j in JOINTS], dtype=float) # noqa: E731 self.kp, self.kd = arr(KP), arr(KD) + self.friction = wp.array([SWING_FRICTION, 0.0, 0.0, 0.0], dtype=float) self.tau_lo, self.tau_hi = wp.zeros(4, dtype=float), wp.zeros(4, dtype=float) self.linkage = hyd.Linkage(self.link_frames, pitch) self.vmax = self.nominal_vmax() @@ -783,6 +797,8 @@ def reset(self): self.rigid_graph = None # new state buffers: record the rigid graph again self.q_ref.assign(self.q0.astype(np.float32)) self.levers = np.zeros(4) + self.spool = np.zeros(4) # spool openings (-1..1, sign = joint direction) after the command response + self.lever_log = collections.deque(maxlen=int((max(max(d) for d in hyd.COMMAND_DEAD.values()) + hyd.SWING_START_DEAD) * self.kwargs["fps"]) + 2) self.auto = False self.fleet.reset() self.dozer.reset() @@ -802,7 +818,7 @@ def reset(self): self.swing_inertia = self.SWING_INERTIA_GUESS self._z_cache = {} self._faces, self.face_log, self.pit_done = {}, [], False - self.face_rest, self.pass_fill = {}, 0.0 # strips set aside after a poor pass (until pass n); this pass's best fill + self.face_rest, self.pass_fill, self.pass_carried = {}, 0.0, 0.0 # strips set aside after a poor pass (until pass n); this pass's best fill and what it carried self.stage_time = 0.0 self.auto_wait = 0.0 self.low_prev, self.low_rate, self.swing_held, self.arm_held = None, 0.0, 0.0, 0.0 @@ -916,6 +932,10 @@ def _stage_z(self, wp_): STRIP_HALF_W = 0.55 # m: half the bucket width PIT_DONE_M3 = 0.3 # no strip's cut holds more than this: the excavation is finished (within reach) POOR_PASS, POOR_REST = 0.3, 12 # a pass bringing back less than this fraction of a full bucket sets its strip aside for this many passes + # in these soils, also a pass carrying less than this fraction to the carrier. A clay strip whose cut takes + # slabs the bucket loses on the way out kept being chosen at about 0.4 t a pass, since its soil stays in the + # pit. Not in sand: what spills on the swing is no sign of a poor strip (resting on it took dry sand from 1.37 to 1.11 t a pass) + POOR_CARRIED = {"clay": 0.5} def _face(self, p): """The cut for pass p: swing offset, reach shift, deepen and the lowest the bucket may go (None in @@ -935,7 +955,9 @@ def _plan_face(self, p): hard = ground_height(cx, cy) dx, dy = cx - SWING_POS[0], cy - SWING_POS[1] best, best_score = None, -1.0 - for psi in self.FACE_PSI: + for psi, rested in ((psi, rested) for rested in (False, True) for psi in self.FACE_PSI): + if rested and best is not None and best["avail_m3"] >= self.PIT_DONE_M3: + break # strips set aside are a fallback, when no other strip has a cut worth taking # psi = 0 digs toward -x, positive toward -y (swing + left) ux, uy = -math.cos(math.radians(psi)), -math.sin(math.radians(psi)) along, across = dx * ux + dy * uy, -dx * uy + dy * ux @@ -943,7 +965,7 @@ def _plan_face(self, p): if shift < 0 and abs(psi) > 10.0: continue # reaching in is for the slope under the machine, straight ahead band = (along > self.EDGE_REACH[0] + shift) & (along < self.EDGE_REACH[1] + shift) & (np.abs(across) < self.STRIP_HALF_W) - if band.sum() < 10 or self.face_rest.get((psi, shift), -1) > p: + if band.sum() < 10 or (self.face_rest.get((psi, shift), -1) > p) != rested: continue # free-flowing soil: from the strip's median surface (the high edges of an earlier cut would set # the cut too shallow and the bucket would pass through the trench); cohesive soil: from its @@ -962,14 +984,19 @@ def _plan_face(self, p): return best def _stage_r(self, wp_, start=False): - """Waypoint reach (m): dig-side stages shift with the current pass's cut, 'swing back' heads for the - next pass's (as _stage_psi).""" - if self.adaptive_face and wp_[0] in self.LANE_STAGES: - return wp_[2] + self._face(self.passes)["shift"] - if self.adaptive_face and wp_[0] == "swing back": - return wp_[2] + self._face(self.passes + (0 if start else 1))["shift"] + """Waypoint reach (m): dig-side stages shift with the current pass's cut, 'swing back' and the approach + head for the next pass's (as _stage_psi).""" + if self.adaptive_face and (wp_[0] in self.LANE_STAGES or wp_[0] == "swing back"): + return wp_[2] + self._face(self._lane_pass(wp_, start))["shift"] return wp_[2] + def _lane_pass(self, wp_, start): + """The pass whose lane a waypoint is in. The count goes up as the approach is reached, so until then + 'swing back' and the approach belong to the next pass: aimed at the current one, the house swung back + toward the new strip, then to the last one for the approach, then across to the new one again while + penetrating (37 deg from -10 to +20 deg: it overshot to +27 deg and the bucket stuck on the pit wall).""" + return self.passes + (1 if wp_[0] == "swing back" or (wp_[0] == "approach" and not start) else 0) + def set_trench(self, deepen=0.25): """Auto cycle digs a single lane and goes deeper every pass (a trench), down to the floor.""" self.adaptive_face = False @@ -978,18 +1005,14 @@ def set_trench(self, deepen=0.25): self._z_cache = {} def _stage_psi(self, wp_, start=False): - """Waypoint swing angle (deg): dig-side stages shift to the current pass's lane; the final - 'swing back' stage already heads for the next pass's lane. As the start of the next segment (after - the pass count went up) 'swing back' is in the current lane.""" - if self.adaptive_face and wp_[0] in self.LANE_STAGES: - return wp_[1] + self._face(self.passes)["psi"] - if self.adaptive_face and wp_[0] == "swing back": - return wp_[1] + self._face(self.passes + (0 if start else 1))["psi"] - if wp_[0] in self.LANE_STAGES: - return wp_[1] + self.LANES[self.passes % len(self.LANES)] - if wp_[0] == "swing back": - return wp_[1] + self.LANES[(self.passes + (0 if start else 1)) % len(self.LANES)] - return wp_[1] + """Waypoint swing angle (deg): dig-side stages shift to the current pass's lane; 'swing back' and the + approach into the next pass already head for the next pass's lane (_lane_pass).""" + if wp_[0] not in self.LANE_STAGES and wp_[0] != "swing back": + return wp_[1] + p = self._lane_pass(wp_, start) + if self.adaptive_face: + return wp_[1] + self._face(p)["psi"] + return wp_[1] + self.LANES[p % len(self.LANES)] def _waypoint_q(self, wp_, start=False): r, phi = self._stage_r(wp_, start), wp_[4] @@ -1064,7 +1087,7 @@ def _clearance(self, local, psi): def _sweep(self, direction, steps=8, ahead=0.07): """House angles it passes through if it brakes from now, plus `ahead` rad more.""" - v, brake = abs(self.qd[0]), SWING_TAU * self.relief / self.swing_inertia + v, brake = abs(self.qd[0]), self._swing_brake() t = np.linspace(0.0, v / brake, steps) d = v * t - 0.5 * brake * t * t return self.q[0] + direction * np.append(d, d[-1] + ahead) @@ -1081,21 +1104,25 @@ def _swing_allowance(self, local, target, direction, rise_to_end): return math.inf k = bad[0] dist = max(abs(psi[k] - self.q[0]) - 0.07, 0.0) - v = math.sqrt(2.0 * SWING_TAU * self.relief / self.swing_inertia * dist) + v = math.sqrt(2.0 * self._swing_brake() * dist) deficit = -float(m[k:].min()) if self.low_rate > 0.02 and deficit <= rise_to_end + 0.02: v = min(v, dist * self.low_rate / deficit) return v - SWING_INERTIA_GUESS = 55e3 # kg m2 about the swing axis, until measured (boom raised, bucket empty) + SWING_INERTIA_GUESS = 110e3 # kg m2 about the swing axis, until measured (boom raised, bucket empty) SWING_STAGE_DEG = 20 # stages that turn the house further than this are swung like an operator does + def _swing_brake(self): + """Deceleration (rad/s2) of the house in neutral: the cross-over reliefs and friction both stop it.""" + return (SWING_TAU * self.relief + SWING_FRICTION) / self.swing_inertia + def _swing_lever(self, target, allow=None): """Operator swing: full lever, then neutral once the house would coast to the target on the cross-over reliefs; small corrections once it has nearly stopped. `allow(direction)` is the fastest the bucket's clearance lets the house swing: the lever is eased to it, or neutral (brake) above it.""" err, v = target - self.q[0], self.qd[0] - brake = SWING_TAU * self.relief / self.swing_inertia + brake = self._swing_brake() stop = v * v / (2 * brake) * 1.1 + 0.02 if abs(v) > 0.15: lever = math.copysign(1.0, err) if (err * v < 0 or abs(err) > stop) else 0.0 @@ -1284,6 +1311,8 @@ def allow(direction): self.shaking = 0.0 # sticky load still in the bucket: shake it out before swinging back self.shakes += 1 return + if b[0] == "swing to truck": + self.pass_carried = self._bucket_fill() # what this pass brings to the carrier if b[0] == "dump": self._after_dump() self.auto_stage = (self.auto_stage + 1) % n @@ -1293,12 +1322,14 @@ def allow(direction): self.low_prev, self.low_rate = None, 0.0 if self.auto_stage == 0: face = self._faces.get(self.passes) if self.adaptive_face else None - if face is not None and self.pass_fill < self.POOR_PASS * self.full_kg: + carried = self.POOR_CARRIED.get(self.soil) + if face is not None and (self.pass_fill < self.POOR_PASS * self.full_kg + or carried is not None and self.pass_carried < carried * self.full_kg): self.face_rest[(face["psi"], face["shift"])] = self.passes + self.POOR_REST # little came out of it for f in self.face_log[-2:]: if f["pass"] == self.passes: f["poor_kg"] = round(self.pass_fill) - self.pass_fill = 0.0 + self.pass_fill, self.pass_carried = 0.0, 0.0 self.passes += 1 self.ease = 0.0 self.curl_out, self.curl_from = None, None @@ -1327,15 +1358,30 @@ def _hydraulics(self): """Levers -> joint speed commands and torque limits for this frame, from the cylinders.""" self.cyl_pts, self.cyl_L, self.cyl_J = self.linkage.state(self.q) spool = self.levers * LEVER_SIGN # desired joint direction and opening + if self.command_response: + spool = self._respond(spool) + self.spool = spool omega, v_cyl = hyd.speeds(spool, self.cyl_J) # swing and cylinders share the pumps - J = np.where(np.abs(self.cyl_J) < hyd.J_MIN, np.copysign(hyd.J_MIN, self.cyl_J), self.cyl_J) - v_cmd = np.concatenate([[omega], v_cyl / J]) + v_cmd = np.concatenate([[omega], v_cyl / hyd.speed_arm(self.cyl_J)]) lo, hi = hyd.torque_limits(self.cyl_J, hyd.P_RELIEF * self.relief, spool[1:]) tau = SWING_TAU * self.relief self.v_cmd.assign(v_cmd.astype(np.float32)) self.tau_lo.assign(np.concatenate([[-tau], lo]).astype(np.float32)) self.tau_hi.assign(np.concatenate([[tau], hi]).astype(np.float32)) + def _respond(self, cmd): + """Spool openings from the lever history: each joint's dead time for the direction it was asked to move + (a longer one when the swing starts from rest), then a first-order lag.""" + self.lever_log.append(cmd.copy()) + n, fps = len(self.lever_log), self.kwargs["fps"] + target = np.zeros(4) + for j, name in enumerate(JOINTS): + extra = hyd.SWING_START_DEAD if j == 0 and abs(self.qd[0]) < 0.02 and abs(self.spool[0]) < 0.01 else 0.0 + ago = [int(round((d + extra) * fps)) for d in hyd.COMMAND_DEAD[name]] # frames, for +/- direction + up, down = (self.lever_log[-1 - k][j] if k < n else 0.0 for k in ago) + target[j] = up if up > 0 else min(down, 0.0) + return self.spool + (target - self.spool) * min(1.0, self.frame_dt / hyd.COMMAND_LAG) + def part_poses(self): """Zone-frame poses (xyz, quaternion xyzw) of the cylinder barrels, rods and linkage plates.""" psi = self.q[0] @@ -1354,7 +1400,7 @@ def _rigid_substeps(self): wp.launch( hydraulics_kernel, dim=4, - inputs=[self.state_0.joint_q, self.state_0.joint_qd, self.v_cmd, self.q_ref, self.kp, self.kd, self.tau_lo, self.tau_hi, self.q_lo, self.q_hi, self.sim_dt], + inputs=[self.state_0.joint_q, self.state_0.joint_qd, self.v_cmd, self.q_ref, self.kp, self.kd, self.tau_lo, self.tau_hi, self.q_lo, self.q_hi, self.friction, self.sim_dt], outputs=[self.control.joint_f, self.torque], ) self.collision.collide(self.state_0, self.contacts) @@ -1557,11 +1603,12 @@ def step(self): self.tau = self.torque.numpy().astype(float) # house inertia about the swing axis, measured while the swing runs at relief (for the auto operator) acc = (self.qd[0] - qd_prev[0]) / self.frame_dt - if abs(self.tau[0]) > 0.95 * SWING_TAU * self.relief and abs(acc) > 0.3 and acc * self.tau[0] > 0: - self.swing_inertia += 0.1 * (abs(self.tau[0] / acc) - self.swing_inertia) + # (speeding up: the relief torque less friction) + if abs(self.tau[0]) > 0.95 * SWING_TAU * self.relief and abs(acc) > 0.3 and acc * self.tau[0] > 0 and acc * self.qd[0] > 0: + self.swing_inertia += 0.1 * ((abs(self.tau[0]) - SWING_FRICTION) / abs(acc) - self.swing_inertia) self.cyl_p, self.cyl_head = hyd.pressures(self.tau[1:], self.cyl_J) # gauges: loaded-side pressure as a fraction of the nominal relief setting - self.press = np.concatenate([[abs(self.tau[0]) / SWING_TAU], self.cyl_p / hyd.P_RELIEF]) # swing: of its 30.4 MPa relief + self.press = np.concatenate([[abs(self.tau[0]) / SWING_TAU], self.cyl_p / hyd.P_RELIEF]) # swing: of its relief BUCKET_LOCAL_BOX = ( np.array([min(BUCKET_SHELL[:, 0].min(), TOOTH_TIP[0]) - PLATE, -BUCKET_W / 2 - PLATE, min(BUCKET_SHELL[:, 1].min(), TOOTH_TIP[1]) - PLATE]), diff --git a/phase2/hydraulics.py b/phase2/hydraulics.py index b7d406a..a154d54 100644 --- a/phase2/hydraulics.py +++ b/phase2/hydraulics.py @@ -4,9 +4,16 @@ * cylinders (Hitachi ZAXIS 200 brochure): boom 2 x bore 120 / rod 85 mm, arm 135 / 95 mm, bucket 115 / 80 mm; implement relief 34.3 MPa (36.3 MPa power boost), swing relief 30.4 MPa; two main pumps of 194 L/min each - * swing: 13.3 min^-1 and 68.9 kN m (ZX200-3 and ZX210-6 spec listings). At the 30.4 MPa swing relief that - torque means 2.27 L/rad at the house, and 13.3 min^-1 then takes 189 L/min, about one pump + * swing: 13.3 min^-1 and 68.9 kN m (ZX200-3 and ZX210-6 spec listings). At the brochure's 30.4 MPa swing + relief that torque means 2.27 L/rad at the house, and 13.3 min^-1 then takes 189 L/min, about one pump * port (overload) reliefs: 39.2 MPa, typical for this class; not confirmed for the ZX200 + * identified from PWRI's ZX200 step-test measurements (1800 min^-1, eco mode, free air; Abe, Matsusaka, + Endo, Yamauchi, Hashimoto, "Dynamics Model of an Excavator in an Open Source Physical Simulator for + Developing Autonomous Construction", ISARC 2025, doi:10.22260/ISARC2025/0054): SWING_*, CYLINDERS and + COMMAND_* below, and phase2/RESULTS.md "Calibration against PWRI's ZX200 step tests". From joint angles and speeds: + swing speed, swing friction, the cylinder flows per direction and the command delays. From the motor + pressures, which are not yet verified (provisional): the swing relief, and so the swing torque and the + house inertia that goes with it * pin positions: found in the PWRI OPERA ZX200 meshes (zx200_ros2, Apache-2.0) by voting for the bore axes of the pin bosses; each mesh is in its URDF link frame (x forward, z up, pins along y). Over the URDF joint limits they give cylinder travels of 1.28 m (boom), 1.465 m (arm) and 1.04 m @@ -23,9 +30,12 @@ * port reliefs: the pump feeds the side the spool opens, capped by the main relief; the other side (or both, with the spool closed) holds an outside load up to the port relief, then gives way * flow: a lever opens its spool in proportion; the cylinder speed is flow / area of the side being - filled, and when the open spools ask for more than the two pumps deliver, all are slowed alike + filled, with its own maximum flow for each side (the valve meters each direction differently, and arm + crowd regenerates rod oil into the head side, so it takes more than the pumps). When the open spools ask + the pumps for more than they deliver, all are slowed alike * swing: a fixed-displacement motor through the swing reduction; speed = flow / displacement, torque - capped at the swing relief both ways (cross-over reliefs: they also brake the house in neutral) + capped at the swing relief both ways (cross-over reliefs: they also brake the house in neutral), and a + Coulomb friction torque (bearing, gear, motor) against the motion * the bucket cylinder drives the bucket through a four-bar: guide link (arm pin G) and side link (bucket pin K) meet the cylinder rod at pin C """ @@ -36,21 +46,41 @@ P_RELIEF = 34.3e6 # Pa, implement circuit P_POWER_BOOST = 36.3e6 -P_PORT = 39.2e6 # Pa, port (overload) reliefs on the cylinder lines -P_SWING = 30.4e6 # Pa, swing relief -SWING_TORQUE = 68.9e3 # N m at the house -SWING_SPEED = 13.3 * 2 * math.pi / 60 # rad/s -SWING_DISP = SWING_TORQUE / P_SWING # m3/rad at the house (motor displacement x reduction) -SWING_FLOW = SWING_SPEED * SWING_DISP # m3/s at full lever +# Pa, port (overload) reliefs on the cylinder lines. PWRI's recordings show the boom's head side briefly at the +# sensor's 41 MPa full scale when a lowering boom is stopped: a spike above the setting, so they don't pin it down +P_PORT = 39.2e6 +SWING_DISP = 68.9e3 / 30.4e6 # m3/rad at the house (motor displacement x reduction): spec torque at the brochure relief +P_SWING = 34.3e6 # Pa, swing relief: peak motor pressure accelerating and braking (PWRI; provisional, brochure 30.4 MPa) +SWING_TORQUE = P_SWING * SWING_DISP # N m at the house, 77.9 kN m +SWING_FRICTION = 16e3 # N m at the house: why the house speeds up more slowly than it brakes (PWRI) +SWING_SPEED = 1.17 # rad/s at full lever (PWRI, 1800 min^-1 eco; the spec's 13.3 min^-1 = 1.39 rad/s is full power) +SWING_FLOW = SWING_SPEED * SWING_DISP # m3/s at full lever, 159 L/min PUMP_FLOW = 2 * 194.0 / 60000.0 # m3/s, two main pumps LINKS = ("house", "boom", "stick", "bucket") +LPM = 1 / 60000.0 # m3/s per L/min -# name: joint index, cylinders, bore, rod, max spool flow (m3/s), head pin (link, x, z), rod pin (link, x, z) +# name: joint index, cylinders, bore, rod, max spool flow (m3/s) (head side, rod side), head pin (link, x, z), +# rod pin (link, x, z). Boom and arm flows give the joint speeds PWRI measured in each direction at full command +# (1800 min^-1, eco; ISARC 2025 above); their flow channels, read as indicative, agree for the arm. The bucket +# flows match its curl and dump speeds with PWRI's bucket angle read as PWRI_BUCKET_OFFSET + ours (provisional); +# they are well above its flow channels (about 230 / 215 L/min), so the four-bar's moment arm may be too long. CYLINDERS = { - "boom": (1, 2, 0.120, 0.085, PUMP_FLOW, ("house", 0.686, 0.247), ("boom", 1.776, 2.249)), - "arm": (2, 1, 0.135, 0.095, PUMP_FLOW, ("boom", 2.276, 2.789), ("stick", -0.778, -0.367)), - "bucket": (3, 1, 0.115, 0.080, PUMP_FLOW / 2, ("stick", -0.248, 0.733), None), # rod end: linkage pin C + "boom": (1, 2, 0.120, 0.085, (375 * LPM, 270 * LPM), ("house", 0.686, 0.247), ("boom", 1.776, 2.249)), # raise, lower + "arm": (2, 1, 0.135, 0.095, (495 * LPM, 265 * LPM), ("boom", 2.276, 2.789), ("stick", -0.778, -0.367)), # crowd, out + "bucket": (3, 1, 0.115, 0.080, (332 * LPM, 315 * LPM), ("stick", -0.248, 0.733), None), # curl, dump; rod end: linkage pin C } +# rad: PWRI's bucket angle less the URDF bucket angle. Their angle reads 0.007 at the dump end of every run and +# is 0.62 more than ours wherever the model's four-bar matches the speed-vs-angle shape of their constant-pilot +# steps (with no offset the model's moment arm collapses toward curl while the machine's doesn't). Not confirmed +# by PWRI yet (provisional); the free-air pressures, also unverified, put the bucket's balance point elsewhere +PWRI_BUCKET_OFFSET = 0.622 + +# command -> spool response of PWRI's ZX200 under its automation controller (velocity commands), for a +# simulator driven the same way: dead time (s) per joint for (+, -) joint direction, a first-order lag (s) on +# the spool, and a dead time on starting the swing from rest (swing parking-brake release) on top of its own +COMMAND_DEAD = {"swing": (0.30, 0.30), "boom": (0.62, 0.42), "stick": (0.55, 0.45), "bucket": (0.33, 0.33)} # boom +: lowering +COMMAND_LAG = 0.15 +SWING_START_DEAD = 0.30 GUIDE_PIN = ("stick", 1.577, 1.878) # guide link on the arm SIDE_PIN = ("bucket", -0.328, 0.548) # side link on the bucket GUIDE_LEN, SIDE_LEN = 0.561, 0.583 @@ -125,7 +155,14 @@ def torque_limits(J, p_relief, spool=(0.0, 0.0, 0.0), p_port=P_PORT): return lo, hi -J_MIN = 0.05 # m/rad: moment arm floor for speed commands near a stroke end (the boom nears toggle there) +J_MIN = 0.05 # m/rad: moment arm floor for speed commands near a stroke end (boom and bucket near toggle there) + + +def speed_arm(J): + """Moment arm dL/dq used to turn cylinder speed into joint speed: J itself away from the stroke ends, easing + onto the J_MIN floor near toggle without a kink, so joint speed stays smooth (within 1.5 % of J above + 2 J_MIN, 0.3 % above 3 J_MIN).""" + return np.copysign((np.abs(J) ** 4 + J_MIN**4) ** 0.25, J) def speeds(spool, J): @@ -136,8 +173,9 @@ def speeds(spool, J): a_head, a_rod = area(name) extend = spool[k + 1] * J[k] > 0 a = a_head if extend else a_rod - flow[k] = abs(spool[k + 1]) * c[4] - v[k] = math.copysign(flow[k] / a, spool[k + 1] * J[k]) + q = abs(spool[k + 1]) * c[4][0 if extend else 1] + v[k] = math.copysign(q / a, spool[k + 1] * J[k]) + flow[k] = min(q, PUMP_FLOW) # from the pumps: arm crowd tops up from its own rod side omega = spool[0] * SWING_SPEED total = flow.sum() + abs(spool[0]) * SWING_FLOW if total > PUMP_FLOW: diff --git a/phase2/logs/haul_bench_lane_fix_long2_clay_1carrier.json b/phase2/logs/haul_bench_lane_fix_long2_clay_1carrier.json new file mode 100644 index 0000000..60f0d1b --- /dev/null +++ b/phase2/logs/haul_bench_lane_fix_long2_clay_1carrier.json @@ -0,0 +1 @@ +{"soil": "clay", "carriers": 1, "sim_s": 1500.0, "stopped_after_passes": null, "realtime_factor": 0.978, "loads": [{"carrier": 0, "departed_s": 192.3, "load_kg": 10638, "loading_s": 192.3, "passes": 10}, {"carrier": 0, "departed_s": 446.0, "load_kg": 11313, "loading_s": 195.7, "passes": 11}, {"carrier": 0, "departed_s": 689.2, "load_kg": 10728, "loading_s": 184.6, "passes": 10}, {"carrier": 0, "departed_s": 988.9, "load_kg": 11409, "loading_s": 240.9, "passes": 12}, {"carrier": 0, "departed_s": 1306.9, "load_kg": 10141, "loading_s": 258.2, "passes": 14}], "trips": [{"depart_t": 192.28, "stages": {"loading": 192.28, "drive out": 7.92, "turn to dump": 7.23, "reverse to dump": 4.27, "tip": 8.02, "dump": 4.83, "lower": 5.0, "return": 4.78, "turn to load": 7.22, "reverse in": 8.8}, "carry_back_kg": 145, "away_s": 58.07}, {"depart_t": 446.02, "stages": {"loading": 195.67, "drive out": 7.92, "turn to dump": 7.23, "reverse to dump": 4.27, "tip": 8.02, "dump": 5.6, "lower": 5.0, "return": 4.58, "turn to load": 7.22, "reverse in": 8.8}, "carry_back_kg": 272, "away_s": 58.63}, {"depart_t": 689.23, "stages": {"loading": 184.58, "drive out": 7.92, "turn to dump": 7.23, "reverse to dump": 4.27, "tip": 8.02, "dump": 5.88, "lower": 5.0, "return": 4.5, "turn to load": 7.22, "reverse in": 8.8}, "carry_back_kg": 268, "away_s": 58.84}, {"depart_t": 988.93, "stages": {"loading": 240.87, "drive out": 7.92, "turn to dump": 7.23, "reverse to dump": 4.27, "tip": 8.02, "dump": 7.18, "lower": 5.0, "return": 4.12, "turn to load": 7.22, "reverse in": 8.8}, "carry_back_kg": 215, "away_s": 59.75}, {"depart_t": 1306.93, "stages": {"loading": 258.25, "drive out": 7.92, "turn to dump": 7.23, "reverse to dump": 4.27, "tip": 8.02, "dump": 5.68, "lower": 5.0, "return": 4.55, "turn to load": 7.22, "reverse in": 8.8}, "carry_back_kg": 325, "away_s": 58.69}], "delivered_t": 53.0, "loaded_t": 58.42, "loaded_t_per_hour": 140.2, "mean_departure_interval_s": 278.6, "t_per_hour": 127.2, "mean_load_kg": 10846.0, "mean_loading_s": 214.3, "carry_back_kg": [145, 272, 268, 215, 325], "mean_away_s": 58.8, "excavator_wait_s": 245.3, "passes": 69, "spoil_settled_t": 47.81, "lost_particles": 1692, "pool_short": 0, "skipped": [{"t": 436.93, "stage": "swing back", "max_err_rad": 0.0}, {"t": 440.95, "stage": "approach", "max_err_rad": 1.072}, {"t": 444.97, "stage": "penetrate", "max_err_rad": 1.07}, {"t": 448.98, "stage": "drag", "max_err_rad": 0.81}, {"t": 453.0, "stage": "drag-curl", "max_err_rad": 0.8}, {"t": 457.02, "stage": "curl", "max_err_rad": 0.665}, {"t": 988.07, "stage": "swing back", "max_err_rad": 0.001}, {"t": 993.58, "stage": "approach", "max_err_rad": 0.058}], "carrier_wait_at_dump_s": 0.0, "carrier_wait_to_leave_s": 0.0, "carrier_wait_to_load_s": 0.0, "spot_empty_s": 294.0, "pit_left_t": 108.7, "pit_done": false, "faces": [[0.0, 0.0], [-20.0, 0.0], [10.0, 0.0], [-30.0, 0.0], [-10.0, 0.0], [20.0, 0.0], [10.0, 0.0], [-30.0, 0.0], [-30.0, 0.0], [20.0, 0.0], [20.0, 0.0], [10.0, 0.0], [-20.0, 0.0], [-20.0, 0.0], [0.0, 0.0], [0.0, 0.0], [-10.0, 0.0], [-10.0, 0.0], [-20.0, 0.0], [-20.0, 0.0], [-30.0, 0.0], [-20.0, 0.0], [-20.0, 0.0], [-20.0, 0.0], [20.0, 0.0], [20.0, 0.0], [20.0, 0.0], [-10.0, 0.0], [-10.0, 0.0], [-10.0, 0.0], [-10.0, 0.0], [-10.0, 0.0], [-30.0, 0.0], [10.0, 0.0], [10.0, 0.0], [10.0, 0.0], [0.0, 0.0], [0.0, 0.0], [0.0, 0.0], [20.0, 0.0], [20.0, 0.0], [10.0, 0.0], [10.0, 0.0], [10.0, 0.0], [10.0, 0.0], [10.0, 0.0], [10.0, 0.0], [10.0, 0.0], [0.0, 0.0], [0.0, 0.0], [0.0, 0.0], [0.0, 0.0], [-10.0, 0.0], [-10.0, 0.0], [-10.0, 0.0], [-10.0, 0.0], [20.0, 0.0], [20.0, 0.0], [20.0, 0.0], [10.0, 0.0], [-40.0, 0.0], [-30.0, 0.0], [-20.0, 0.0], [0.0, 0.0], [0.0, 0.0], [-20.0, 0.0], [-20.0, 0.0], [-10.0, 0.0], [-10.0, 0.0], [10.0, 0.0]], "curl_gain_kg": 161, "curl_tears": 0, "mean_carried_kg": 963, "mean_dumped_kg": 811, "thin_passes": 18, "pass_log": [{"pass": 0, "t": 0.0, "face": [0.0, 0.0, 1.39], "dig_max_kg": 1240, "early_curl": true, "skips": 0, "at_swing_kg": 1227, "carried_kg": 1257, "left_kg": 92}, {"pass": 1, "t": 15.8, "face": [-20.0, 0.0, 1.37], "dig_max_kg": 1239, "early_curl": true, "skips": 0, "at_swing_kg": 1128, "carried_kg": 1094, "left_kg": 100}, {"pass": 2, "t": 31.8, "face": [10.0, 0.0, 1.35], "dig_max_kg": 1128, "early_curl": true, "skips": 0, "at_swing_kg": 1115, "carried_kg": 1133, "left_kg": 161}, {"pass": 3, "t": 49.0, "face": [-30.0, 0.0, 1.28], "dig_max_kg": 1279, "early_curl": true, "skips": 0, "at_swing_kg": 1245, "carried_kg": 1282, "left_kg": 299}, {"pass": 4, "t": 66.4, "face": [-10.0, 0.0, 1.26], "dig_max_kg": 1357, "early_curl": true, "skips": 0, "at_swing_kg": 1338, "carried_kg": 1360, "left_kg": 222}, {"pass": 5, "t": 84.4, "face": [20.0, 0.0, 1.15], "dig_max_kg": 1351, "early_curl": true, "skips": 0, "at_swing_kg": 917, "carried_kg": 964, "left_kg": 36}, {"pass": 6, "t": 102.1, "face": [10.0, 0.0, 0.85], "dig_max_kg": 1220, "early_curl": false, "skips": 0, "at_swing_kg": 1206, "carried_kg": 1272, "left_kg": 132}, {"pass": 7, "t": 120.3, "face": [-30.0, 0.0, 0.77], "dig_max_kg": 1220, "early_curl": false, "skips": 0, "at_swing_kg": 1047, "carried_kg": 1076, "left_kg": 295}, {"pass": 8, "t": 137.3, "face": [-30.0, 0.0, 0.85], "dig_max_kg": 1109, "early_curl": false, "skips": 0, "at_swing_kg": 1083, "carried_kg": 1112, "left_kg": 166}, {"pass": 9, "t": 157.1, "face": [20.0, 0.0, 0.68], "dig_max_kg": 1170, "early_curl": false, "skips": 0, "at_swing_kg": 1157, "carried_kg": 1212, "left_kg": 17}, {"pass": 10, "t": 176.7, "face": [20.0, 0.0, 0.98], "dig_max_kg": 296, "early_curl": false, "skips": 0, "at_swing_kg": 296, "carried_kg": 358, "left_kg": 40}, {"pass": 11, "t": 194.2, "face": [10.0, 0.0, 1.04], "dig_max_kg": 1317, "early_curl": true, "skips": 0, "at_swing_kg": 1362, "carried_kg": 1337, "left_kg": 95}, {"pass": 12, "t": 258.8, "face": [-20.0, 0.0, 0.61], "dig_max_kg": 1300, "early_curl": false, "skips": 0, "at_swing_kg": 1086, "carried_kg": 1132, "left_kg": 102}, {"pass": 13, "t": 274.6, "face": [-20.0, 0.0, 1.07], "dig_max_kg": 1300, "early_curl": true, "skips": 0, "at_swing_kg": 1296, "carried_kg": 1350, "left_kg": 109}, {"pass": 14, "t": 290.9, "face": [0.0, 0.0, 0.57], "dig_max_kg": 1299, "early_curl": false, "skips": 0, "at_swing_kg": 1164, "carried_kg": 1241, "left_kg": 32}, {"pass": 15, "t": 307.1, "face": [0.0, 0.0, 1.05], "dig_max_kg": 1387, "early_curl": true, "skips": 0, "at_swing_kg": 1359, "carried_kg": 1430, "left_kg": 342}, {"pass": 16, "t": 325.8, "face": [-10.0, 0.0, 0.44], "dig_max_kg": 1379, "early_curl": false, "skips": 0, "at_swing_kg": 1113, "carried_kg": 1143, "left_kg": 169}, {"pass": 17, "t": 343.1, "face": [-10.0, 0.0, 1.07], "dig_max_kg": 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"unspread_m3": 0.69}} diff --git a/phase2/logs/haul_bench_lane_fix_long_loam_1carrier.json b/phase2/logs/haul_bench_lane_fix_long_loam_1carrier.json new file mode 100644 index 0000000..b2a328b --- /dev/null +++ b/phase2/logs/haul_bench_lane_fix_long_loam_1carrier.json @@ -0,0 +1 @@ +{"soil": "loam", "carriers": 1, "sim_s": 1500.0, "stopped_after_passes": null, "realtime_factor": 0.985, "loads": [{"carrier": 0, "departed_s": 129.8, "load_kg": 10774, "loading_s": 129.8, "passes": 7}, {"carrier": 0, "departed_s": 329.7, "load_kg": 10597, "loading_s": 142.8, "passes": 8}, {"carrier": 0, "departed_s": 537.8, "load_kg": 10503, "loading_s": 150.9, "passes": 8}, {"carrier": 0, "departed_s": 729.9, "load_kg": 11383, "loading_s": 134.8, "passes": 7}, {"carrier": 0, "departed_s": 899.8, "load_kg": 10886, "loading_s": 112.0, "passes": 6}, {"carrier": 0, "departed_s": 1097.9, "load_kg": 9408, "loading_s": 139.8, "passes": 8}], "trips": [{"depart_t": 129.82, "stages": {"loading": 129.82, "drive 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"carriers": 1, "sim_s": 612.5, "stopped_after_passes": 25, "realtime_factor": 0.204, "loads": [{"carrier": 0, "departed_s": 182.6, "load_kg": 9512, "loading_s": 182.6, "passes": 8}, {"carrier": 0, "departed_s": 315.4, "load_kg": 9165, "loading_s": 76.0, "passes": 4}, {"carrier": 0, "departed_s": 489.9, "load_kg": 10367, "loading_s": 117.9, "passes": 6}], "trips": [{"depart_t": 182.62, "stages": {"loading": 182.62, "drive out": 7.92, "turn to dump": 7.23, "reverse to dump": 4.27, "tip": 8.02, "dump": 3.03, "lower": 5.0, "return": 5.23, "turn to load": 7.22, "reverse in": 8.8}, "carry_back_kg": 113, "away_s": 56.71}, {"depart_t": 315.35, "stages": {"loading": 76.02, "drive out": 7.92, "turn to dump": 7.23, "reverse to dump": 4.27, "tip": 8.02, "dump": 3.03, "lower": 5.0, "return": 5.23, "turn to load": 7.22, "reverse in": 8.8}, "carry_back_kg": 81, "away_s": 56.72}, {"depart_t": 489.93, "stages": {"loading": 117.87, "drive out": 7.92, "turn to dump": 7.23, "reverse to dump": 4.27, "tip": 8.02, "dump": 3.03, "lower": 5.0, "return": 5.23, "turn to load": 7.22, "reverse in": 8.8}, "carry_back_kg": 282, "away_s": 56.72}], "delivered_t": 28.57, "loaded_t": 35.47, "loaded_t_per_hour": 208.5, "mean_departure_interval_s": 153.6, "t_per_hour": 167.9, "mean_load_kg": 9681.0, "mean_loading_s": 125.5, "carry_back_kg": [113, 81, 282], "mean_away_s": 56.7, "excavator_wait_s": 143.4, "passes": 25, "spoil_settled_t": 28.53, "lost_particles": 4163, "pool_short": 139, "skipped": [{"t": 136.47, "stage": "swing to truck", "max_err_rad": 0.134}, {"t": 146.78, "stage": "swing back", "max_err_rad": 0.062}, {"t": 150.8, "stage": "approach", "max_err_rad": 1.417}, {"t": 154.82, "stage": "penetrate", "max_err_rad": 1.413}, {"t": 158.83, "stage": "drag", "max_err_rad": 1.407}, {"t": 162.85, "stage": "drag-curl", "max_err_rad": 1.391}, {"t": 166.87, "stage": "curl", "max_err_rad": 1.346}, {"t": 177.28, "stage": "swing to truck", "max_err_rad": 0.414}], "carrier_wait_at_dump_s": 0.0, "carrier_wait_to_leave_s": 0.0, "carrier_wait_to_load_s": 0.0, "spot_empty_s": 170.2, "pit_left_t": 117.1, "pit_done": false, "faces": [[0.0, 0.0], [0.0, 0.0], [-10.0, 0.0], [-10.0, 0.0], [0.0, 0.0], [0.0, 0.0], [-10.0, 0.0], [-10.0, 0.0], [-10.0, 0.0], [-10.0, 0.0], [-10.0, 0.0], [-10.0, 0.0], [-10.0, 0.0], [-10.0, 0.0], [-10.0, 0.0], [-10.0, 0.0], [10.0, 0.0], [10.0, 0.0], [10.0, 0.0], [-10.0, 0.0], [10.0, 0.0], [10.0, 0.0], [-10.0, 0.0], [0.0, 0.0], [0.0, 0.0], [-10.0, 0.0]], "curl_gain_kg": 0, "curl_tears": null, "mean_carried_kg": 1336, "mean_dumped_kg": 1331, "thin_passes": 1, "pass_log": [{"pass": 0, "t": 0.0, "face": [0.0, 0.0, 1.39], "dig_max_kg": 902, "early_curl": false, "skips": 0, "at_swing_kg": 894, "carried_kg": 588, "left_kg": 1}, {"pass": 1, "t": 15.7, "face": [0.0, 0.0, 1.48], "dig_max_kg": 1629, "early_curl": false, "skips": 0, "at_swing_kg": 1629, "carried_kg": 1326, "left_kg": 7}, {"pass": 2, "t": 31.2, "face": [-10.0, 0.0, 1.42], "dig_max_kg": 1603, "early_curl": false, "skips": 0, "at_swing_kg": 1245, "carried_kg": 947, "left_kg": 1}, {"pass": 3, "t": 48.3, "face": [-10.0, 0.0, 1.49], "dig_max_kg": 1711, "early_curl": false, "skips": 0, "at_swing_kg": 1711, "carried_kg": 1319, "left_kg": 2}, {"pass": 4, "t": 65.6, "face": [0.0, 0.0, 1.49], "dig_max_kg": 1703, "early_curl": false, "skips": 0, "at_swing_kg": 1642, "carried_kg": 1307, "left_kg": 1}, {"pass": 5, "t": 82.9, "face": [0.0, 0.0, 1.63], "dig_max_kg": 1914, "early_curl": false, "skips": 0, "at_swing_kg": 1914, "carried_kg": 1417, "left_kg": 8}, {"pass": 6, "t": 99.7, "face": [-10.0, 0.0, 1.65], "dig_max_kg": 1841, "early_curl": false, "skips": 0, "at_swing_kg": 1841, "carried_kg": 1351, "left_kg": 1}, {"pass": 7, "t": 118.6, "face": [-10.0, 0.0, 1.8], "dig_max_kg": 2064, "early_curl": false, "skips": 2, "at_swing_kg": 2064, "carried_kg": 1595, "left_kg": 13}, {"pass": 8, "t": 146.8, "face": [-10.0, 0.0, 1.65], "dig_max_kg": 2054, "early_curl": false, "skips": 6, "at_swing_kg": 551, "carried_kg": 908, "left_kg": 2}, {"pass": 9, "t": 184.0, "face": [-10.0, 0.0, 1.65], "dig_max_kg": 2003, "early_curl": false, "skips": 0, "at_swing_kg": 1768, "carried_kg": 1312, "left_kg": 15}, {"pass": 10, "t": 246.7, "face": [-10.0, 0.0, 1.7], "dig_max_kg": 2025, "early_curl": false, "skips": 0, "at_swing_kg": 2025, "carried_kg": 1730, "left_kg": 28}, {"pass": 11, "t": 264.4, "face": [-10.0, 0.0, 1.63], "dig_max_kg": 2028, "early_curl": false, "skips": 0, "at_swing_kg": 2028, "carried_kg": 1605, "left_kg": 3}, {"pass": 12, "t": 282.0, "face": [-10.0, 0.0, 1.63], "dig_max_kg": 2019, "early_curl": false, "skips": 0, "at_swing_kg": 2019, "carried_kg": 1526, "left_kg": 2}, {"pass": 13, "t": 299.9, "face": [-10.0, 0.0, 1.69], "dig_max_kg": 2038, "early_curl": false, "skips": 0, "at_swing_kg": 2038, "carried_kg": 1708, "left_kg": 5}, {"pass": 14, "t": 316.9, "face": [-10.0, 0.0, 1.63], "dig_max_kg": 2030, "early_curl": false, "skips": 0, "at_swing_kg": 1797, "carried_kg": 1409, "left_kg": 1}, {"pass": 15, "t": 379.3, "face": [-10.0, 0.0, 1.62], "dig_max_kg": 2017, "early_curl": false, "skips": 0, "at_swing_kg": 2002, "carried_kg": 1544, "left_kg": 1}, {"pass": 16, "t": 398.0, "face": [10.0, 0.0, 1.46], "dig_max_kg": 1996, "early_curl": false, "skips": 0, "at_swing_kg": 962, "carried_kg": 688, "left_kg": 0}, {"pass": 17, "t": 416.6, "face": [10.0, 0.0, 1.64], "dig_max_kg": 1670, "early_curl": false, "skips": 0, "at_swing_kg": 1670, "carried_kg": 1250, "left_kg": 4}, {"pass": 18, "t": 433.6, "face": [10.0, 0.0, 1.57], "dig_max_kg": 1831, "early_curl": false, "skips": 0, "at_swing_kg": 1831, "carried_kg": 1239, "left_kg": 0}, {"pass": 19, "t": 451.0, "face": [-10.0, 0.0, 1.59], "dig_max_kg": 2045, "early_curl": false, "skips": 0, "at_swing_kg": 2045, "carried_kg": 1678, "left_kg": 5}, {"pass": 20, "t": 471.6, "face": [10.0, 0.0, 1.52], "dig_max_kg": 2029, "early_curl": false, "skips": 0, "at_swing_kg": 1784, "carried_kg": 1377, "left_kg": 2}, {"pass": 21, "t": 491.8, "face": [10.0, 0.0, 1.57], "dig_max_kg": 1892, "early_curl": false, "skips": 0, "at_swing_kg": 1584, "carried_kg": 1229, "left_kg": 1}, {"pass": 22, "t": 554.1, "face": [-10.0, 0.0, 1.6], "dig_max_kg": 2005, "early_curl": false, "skips": 0, "at_swing_kg": 2005, "carried_kg": 1679, "left_kg": 10}, {"pass": 23, "t": 574.1, "face": [0.0, 0.0, 1.52], "dig_max_kg": 1982, "early_curl": false, "skips": 0, "at_swing_kg": 1767, "carried_kg": 1300, "left_kg": 10}, {"pass": 24, "t": 592.6, "face": [0.0, 0.0, 1.64], "dig_max_kg": 2027, "early_curl": false, "skips": 0, "at_swing_kg": 2027, "carried_kg": 1371, "left_kg": 1}], "dozer": {"passes": 9, "push_m": 43.9, "work_MJ": 0.35, "load_lifts": 1, "lifts_raised": 1, "parked_s": 422.43, "working_s": 190.1, "peak_kN": 49.22, "slip_s": 0.0, "futile_passes": 2, "mean_push_kN": [9.9, 4.5, 7.3, 7.1, 10.7, 0.3, 0.3, 8.7, 4.7]}, "spread": {"design_z_above_ground": 0.6, "area_m2": 61.2, "covered_m2": 40.0, "rms_from_grade_m": 0.216, "max_above_grade_m": 0.28, "at_grade_fraction": 0.29, "unspread_m3": 0.21}} diff --git a/phase2/logs/haul_quick25_main_loam_1carrier.json b/phase2/logs/haul_quick25_main_loam_1carrier.json new file mode 100644 index 0000000..81bce56 --- /dev/null +++ b/phase2/logs/haul_quick25_main_loam_1carrier.json @@ -0,0 +1 @@ +{"soil": "loam", "carriers": 1, "sim_s": 618.2, "stopped_after_passes": 25, "realtime_factor": 0.209, "loads": [{"carrier": 0, "departed_s": 207.6, "load_kg": 10443, "loading_s": 207.6, "passes": 9}, {"carrier": 0, "departed_s": 354.3, "load_kg": 10045, "loading_s": 89.9, "passes": 5}, {"carrier": 0, "departed_s": 552.4, "load_kg": 10065, "loading_s": 141.2, "passes": 7}], "trips": [{"depart_t": 207.6, "stages": {"loading": 207.6, "drive out": 7.92, "turn to dump": 7.23, "reverse to dump": 4.27, "tip": 8.02, "dump": 3.03, "lower": 5.0, "return": 5.23, "turn to load": 7.22, "reverse in": 8.8}, "carry_back_kg": 50, "away_s": 56.72}, {"depart_t": 354.27, "stages": {"loading": 89.95, "drive out": 7.92, "turn to dump": 7.23, "reverse to dump": 4.27, "tip": 8.02, "dump": 3.35, "lower": 5.0, "return": 5.15, "turn to load": 7.22, "reverse in": 8.8}, "carry_back_kg": 440, "away_s": 56.95}, {"depart_t": 552.42, "stages": {"loading": 141.2, "drive out": 7.92, "turn to dump": 7.23, "reverse to dump": 4.27, "tip": 8.02, "dump": 3.7, "lower": 5.0, "return": 5.07, "turn to load": 7.22, "reverse in": 8.8}, "carry_back_kg": 152, "away_s": 57.21}], "delivered_t": 29.91, "loaded_t": 32.17, "loaded_t_per_hour": 187.4, "mean_departure_interval_s": 172.4, "t_per_hour": 174.2, "mean_load_kg": 10184.0, "mean_loading_s": 146.2, "carry_back_kg": [50, 440, 152], "mean_away_s": 57.0, "excavator_wait_s": 141.8, "passes": 25, "spoil_settled_t": 20.47, "lost_particles": 1405, "pool_short": 0, "skipped": [{"t": 79.38, "stage": "penetrate", "max_err_rad": 0.126}, {"t": 83.4, "stage": "drag", "max_err_rad": 0.134}, {"t": 146.88, "stage": "penetrate", "max_err_rad": 0.241}, {"t": 150.9, "stage": "drag", "max_err_rad": 0.257}, {"t": 154.92, "stage": "drag-curl", "max_err_rad": 0.207}, {"t": 476.63, "stage": "penetrate", "max_err_rad": 0.15}, {"t": 480.65, "stage": "drag", "max_err_rad": 0.176}, {"t": 484.67, "stage": "drag-curl", "max_err_rad": 0.188}], "carrier_wait_at_dump_s": 0.0, "carrier_wait_to_leave_s": 0.0, "carrier_wait_to_load_s": 0.0, "spot_empty_s": 170.9, "pit_left_t": 144.5, "pit_done": false, "faces": [[0.0, 0.0], [-20.0, 0.0], [10.0, 0.0], [-10.0, 0.0], [20.0, 0.0], [-30.0, 0.0], [-30.0, 0.0], [20.0, 0.0], [20.0, 0.0], [0.0, 0.0], [0.0, 0.0], [-10.0, 0.0], [-10.0, 0.0], [-20.0, 0.0], [-20.0, 0.0], [-30.0, 0.0], [-20.0, 0.0], [-20.0, 0.0], [-20.0, 0.0], [-20.0, 0.0], [20.0, 0.0], [20.0, 0.0], [10.0, 0.0], [10.0, 0.0], [0.0, 0.0], [0.0, 0.0]], "curl_gain_kg": 120, "curl_tears": null, "mean_carried_kg": 1220, "mean_dumped_kg": 1116, "thin_passes": 3, "pass_log": [{"pass": 0, "t": 0.0, "face": [0.0, 0.0, 1.39], "dig_max_kg": 1113, "early_curl": true, "skips": 0, "at_swing_kg": 1075, "carried_kg": 1170, "left_kg": 12}, {"pass": 1, "t": 14.8, "face": [-20.0, 0.0, 1.37], "dig_max_kg": 1191, "early_curl": true, "skips": 0, "at_swing_kg": 1138, "carried_kg": 1164, "left_kg": 15}, {"pass": 2, "t": 32.6, "face": [10.0, 0.0, 1.35], "dig_max_kg": 1235, "early_curl": true, "skips": 0, "at_swing_kg": 364, "carried_kg": 463, "left_kg": 91}, {"pass": 3, "t": 51.3, "face": [-10.0, 0.0, 1.23], "dig_max_kg": 1560, "early_curl": false, "skips": 0, "at_swing_kg": 1525, "carried_kg": 1546, "left_kg": 22}, {"pass": 4, "t": 70.4, "face": [20.0, 0.0, 1.13], "dig_max_kg": 1554, "early_curl": false, "skips": 2, "at_swing_kg": 765, "carried_kg": 978, "left_kg": 12}, {"pass": 5, "t": 97.0, "face": [-30.0, 0.0, 0.83], "dig_max_kg": 1185, "early_curl": false, "skips": 0, "at_swing_kg": 1162, "carried_kg": 1265, "left_kg": 87}, {"pass": 6, "t": 118.6, "face": [-30.0, 0.0, 1.09], "dig_max_kg": 1410, "early_curl": false, "skips": 0, "at_swing_kg": 1214, "carried_kg": 1377, "left_kg": 399}, {"pass": 7, "t": 137.4, "face": [20.0, 0.0, 0.73], "dig_max_kg": 1230, "early_curl": false, "skips": 3, "at_swing_kg": 0, "carried_kg": 0, "left_kg": 1}, {"pass": 8, "t": 166.7, "face": [20.0, 0.0, 0.74], "dig_max_kg": 1382, "early_curl": false, "skips": 0, "at_swing_kg": 1350, "carried_kg": 1475, "left_kg": 323}, {"pass": 9, "t": 186.5, "face": [0.0, 0.0, 0.69], "dig_max_kg": 1354, "early_curl": false, "skips": 0, "at_swing_kg": 1083, "carried_kg": 1298, "left_kg": 326}, {"pass": 10, "t": 209.2, "face": [0.0, 0.0, 1.17], "dig_max_kg": 1468, "early_curl": false, "skips": 0, "at_swing_kg": 1554, "carried_kg": 1503, "left_kg": 97}, {"pass": 11, "t": 272.0, "face": [-10.0, 0.0, 0.61], "dig_max_kg": 1376, "early_curl": false, "skips": 0, "at_swing_kg": 1364, "carried_kg": 1500, "left_kg": 55}, {"pass": 12, "t": 289.1, "face": [-10.0, 0.0, 1.16], "dig_max_kg": 1376, "early_curl": true, "skips": 0, "at_swing_kg": 1282, "carried_kg": 1400, "left_kg": 28}, {"pass": 13, "t": 304.8, "face": [-20.0, 0.0, 0.62], "dig_max_kg": 1389, "early_curl": false, "skips": 0, "at_swing_kg": 1378, "carried_kg": 1409, "left_kg": 108}, {"pass": 14, "t": 321.9, "face": [-20.0, 0.0, 1.11], "dig_max_kg": 1389, "early_curl": true, "skips": 0, "at_swing_kg": 1089, "carried_kg": 1292, "left_kg": 67}, {"pass": 15, "t": 337.8, "face": [-30.0, 0.0, 0.8], "dig_max_kg": 1521, "early_curl": false, "skips": 0, "at_swing_kg": 1458, "carried_kg": 1528, "left_kg": 86}, {"pass": 16, "t": 355.4, "face": [-20.0, 0.0, 0.58], "dig_max_kg": 1526, "early_curl": false, "skips": 0, "at_swing_kg": 1617, "carried_kg": 1556, "left_kg": 79}, {"pass": 17, "t": 418.4, "face": [-20.0, 0.0, 1.14], "dig_max_kg": 1526, "early_curl": true, "skips": 0, "at_swing_kg": 1246, "carried_kg": 1332, "left_kg": 20}, {"pass": 18, "t": 434.3, "face": [-20.0, 0.0, 0.57], "dig_max_kg": 1429, "early_curl": false, "skips": 0, "at_swing_kg": 1428, "carried_kg": 1408, "left_kg": 19}, {"pass": 19, "t": 450.8, "face": [-20.0, 0.0, 1.1], "dig_max_kg": 1429, "early_curl": true, "skips": 0, "at_swing_kg": 1128, "carried_kg": 1207, "left_kg": 42}, {"pass": 20, "t": 467.7, "face": [20.0, 0.0, 0.88], "dig_max_kg": 1129, "early_curl": false, "skips": 3, "at_swing_kg": 194, "carried_kg": 381, "left_kg": 216}, {"pass": 21, "t": 497.0, "face": [20.0, 0.0, 0.95], "dig_max_kg": 1129, "early_curl": false, "skips": 0, "at_swing_kg": 1115, "carried_kg": 1190, "left_kg": 27}, {"pass": 22, "t": 515.7, "face": [10.0, 0.0, 0.53], "dig_max_kg": 1129, "early_curl": false, "skips": 0, "at_swing_kg": 1070, "carried_kg": 1256, "left_kg": 117}, {"pass": 23, "t": 535.5, "face": [10.0, 0.0, 1.15], "dig_max_kg": 1251, "early_curl": true, "skips": 0, "at_swing_kg": 1092, "carried_kg": 1313, "left_kg": 303}, {"pass": 24, "t": 554.1, "face": [0.0, 0.0, 0.73], "dig_max_kg": 1501, "early_curl": false, "skips": 0, "at_swing_kg": 1551, "carried_kg": 1482, "left_kg": 45}], "dozer": {"passes": 5, "push_m": 42.95, "work_MJ": 0.76, "load_lifts": 15, "lifts_raised": 1, "parked_s": 455.55, "working_s": 162.62, "peak_kN": 85.7, "slip_s": 0.32, "futile_passes": 0, "mean_push_kN": [12.2, 19.9, 12.6, 12.7, 24.0]}, "spread": {"design_z_above_ground": 0.6, "area_m2": 61.2, "covered_m2": 39.1, "rms_from_grade_m": 0.355, "max_above_grade_m": 0.9, "at_grade_fraction": 0.18, "unspread_m3": 1.4}} diff --git a/phase2/ros_server.py b/phase2/ros_server.py index 725012a..d9d9032 100644 --- a/phase2/ros_server.py +++ b/phase2/ros_server.py @@ -155,7 +155,7 @@ async def run(self): async def main_async(args): - sim = ex.ExcavatorSim(soil=args.soil, carriers=args.carriers) + sim = ex.ExcavatorSim(soil=args.soil, carriers=args.carriers, command_response=args.command_response) sim.auto = args.autopilot server = Server(sim, sensors.SensorRig(sim), fast=args.fast) srv = await asyncio.start_server(server.handle, args.host, args.port) @@ -172,6 +172,7 @@ def main(): ap.add_argument("--carriers", type=int, default=1, choices=(1, 2), help="crawler carriers in the haul cycle") ap.add_argument("--autopilot", action="store_true", help="start with the built-in operator driving") ap.add_argument("--fast", action="store_true", help="run as fast as possible instead of in real time") + ap.add_argument("--command-response", action="store_true", help="levers reach the spools with the measured ZX200 dead time and lag (hydraulics.COMMAND_DEAD)") asyncio.run(main_async(ap.parse_args()))