arXiv subjects

Sean Costello

Publications and source records attributed to Sean Costello.

2 recordsLinked to original sources

arXiv2026

High Precision Hydraulic Excavator Control for Heavy-Duty Grading

High-precision heavy-duty grading is a common step in earthworks, traditionally carried out manually by skilled operators. Removing a significant amount of material while achieving a high-precision surface requires substantial machine-specific experience. Different hydraulic architectures react differently to operator inputs and soil interaction forces, which makes generalizable controllers challenging. In this paper, we present an autonomous controller that achieves high-precision grading at expert-operator speed on Load Sensing and Negative Flow Control machines alike. We split our controller into two parts: (1) a hydraulic-aware low-level loop that is hydraulic architecture-specific and (2) a path-tracking layer that coordinates joint motions and responses. Through a calibration process, our technique is applicable to load-sensing and negative-flow-control machinery. To showcase its versatility, we benchmark our approach on two excavators with different hydraulics and compare it against a commercial state-of-the-art solution. Our technique (RMSE 1.8~cm) outperforms the commercial solution (RMSE 4.7~cm) in precision by a factor of 2.6 and improves machine usage by leveraging the maximum function pressure, as opposed to commercial solutions that stall prematurely.

cs.RO↗

arXiv2025

Calibrated Dynamic Modeling for Force and Payload Estimation in Hydraulic Machinery

Accurate real-time estimation of end effector interaction forces in hydraulic excavators is a key enabler for advanced automation in heavy machinery. Accurate knowledge of these forces allows improved, precise grading and digging maneuvers. To address these challenges, we introduce a high-accuracy, retrofittable 2D force- and payload estimation algorithm that does not impose additional requirements on the operator regarding trajectory, acceleration or the use of the slew joint. The approach is designed for retrofittability, requires minimal calibration and no prior knowledge of machine-specific dynamic characteristics. Specifically, we propose a method for identifying a dynamic model, necessary to estimate both end effector interaction forces and bucket payload during normal operation. Our optimization-based payload estimation achieves a full-scale payload accuracy of 1%. On a standard 25 t excavator, the online force measurement from pressure and inertial measurements achieves a direction accuracy of 13 degree and a magnitude accuracy of 383 N. The method's accuracy and generalization capability are validated on two excavator platforms of different type and weight classes. We benchmark our payload estimation against a classical quasistatic method and a commercially available system. Our system outperforms both in accuracy and precision.

cs.RO↗