System and method for determining lifting capacity of a machine

Abstract

A system for determining a lift capacity of a pipelayer is provided. The system includes a load sensor configured to generate a signal indicative of a load suspended from a hook, an angle sensor configured to generate a signal indicative of an angular position of a chassis relative to the ground, a boom position sensor configured to generate a signal indicative of a position of a boom relative to a chassis, and a counterweight position sensor configured to generate a signal indicative of a position of a counterweight relative to the chassis. The system also includes a controller configured to receive the signal from each of the load sensor, the angle sensor, the boom position sensor, and the counterweight position sensor. The controller is further configured to determine a lift capacity of the pipelayer based at least in part on the received signals.

Description

Technical Field

[0001] This invention relates to a system and method for determining the lifting capacity of a machine. More specifically, this invention relates to a system and method for determining the lifting capacity of machines such as pipe-laying machines. Background Technology

[0002] A machine, such as a pipe-laying machine, includes a boom assembly for raising and lowering loads during lifting operations, such as pipe-laying operations. The machine may also include a counterweight system to provide the machine with variable load lifting capacity and to stabilize the machine during the lifting operation. During the lifting operation, the operator of the machine can position the counterweight system in any position, either a retracted position, an extended position, or any intermediate position between the retracted and extended positions. In most cases, the machine may have its lowest lifting capacity in the retracted position of the counterweight system and its highest lifting capacity in the extended position of the counterweight system.

[0003] During lifting operations, operators may need to visually determine the position of the counterweight system and estimate the machine's actual and / or maximum lifting capacity based on operational judgment and skill. In some cases, this can increase the likelihood of machine overturning or damage due to load imbalance, overloading, or incorrect operator judgment. Thus, controlling the machine and lifting operations can become highly operator-dependent tasks, increasing operator effort and reducing machine performance. Therefore, an improved system and method are needed to determine the lifting capacity of such machines.

[0004] U.S. Patent Application No. 2016 / 0169413 describes a pipe-laying machine having a base frame, a boom movable relative to the base frame in a first lateral direction, and a counterweight movable relative to the base frame in a second lateral direction. The second lateral direction is opposite to the first lateral direction and varies between an extended position and a retracted position. A counterweight position sensor determines the current position of the counterweight and generates a counterweight position signal. An operator interface operatively connected to the counterweight position sensor displays the counterweight position information based on the counterweight position signal. Summary of the Invention

[0005] In one aspect of the invention, a system for determining the lifting capacity of a pipe-laying machine is provided. The system includes a load sensor arranged in association with a hook of the pipe-laying machine. The load sensor is configured to generate a signal indicating the load suspended from the hook. The system includes an angle sensor arranged on the chassis of the pipe-laying machine. The angle sensor is configured to generate a signal indicating the angular position of the chassis relative to the ground. The system includes a boom position sensor arranged in association with a boom of the pipe-laying machine. The boom position sensor is configured to generate a signal indicating the position of the boom relative to the underframe of the pipe-laying machine. The system also includes a counterweight position sensor arranged in association with a counterweight system of the pipe-laying machine. The counterweight position sensor is configured to generate a signal indicating the position of the counterweight relative to the underframe. The system further includes a controller communicatively coupled to each of the load sensor, angle sensor, boom position sensor, and counterweight position sensor. The controller is configured to receive signals from each of the load sensor, angle sensor, boom position sensor, and counterweight position sensor. The controller is also configured to determine the pipelaying machine’s lifting capacity based at least in part on signals received from each of the load sensor, angle sensor, boom position sensor and counterweight position sensor.

[0006] In another aspect of the invention, the pipe-laying machine includes a chassis. The pipe-laying machine includes a base frame coupled to the chassis. The pipe-laying machine includes a boom movably coupled to the base frame. The boom includes a hook suspended therefrom. The pipe-laying machine includes a counterweight system movably coupled to the base frame and arranged opposite the boom. The pipe-laying machine includes a load sensor arranged in association with the hook. The load sensor is configured to generate a signal indicating the load suspended from the hook. The pipe-laying machine includes an angle sensor arranged on the chassis. The angle sensor is configured to generate a signal indicating the angular position of the chassis relative to the ground. The pipe-laying machine includes a boom position sensor arranged in association with the boom. The boom position sensor is configured to generate a signal indicating the position of the boom relative to the base frame. The pipe-laying machine also includes a counterweight position sensor arranged in association with the counterweight system. The counterweight position sensor is configured to generate a signal indicating the position of the counterweight relative to the base frame. The pipe-laying machine further includes a controller communicatively coupled to each of the load sensor, angle sensor, boom position sensor, and counterweight position sensor. The controller is configured to receive signals from each of the load sensor, angle sensor, boom position sensor, and counterweight position sensor. The controller is also configured to determine the lifting capacity of the pipe-laying machine based at least in part on the signals received from each of the load sensor, angle sensor, boom position sensor, and counterweight position sensor.

[0007] In another aspect of the invention, a method for determining the lifting capacity of a pipe-laying machine is provided. The method includes receiving a signal indicating a load suspended from the hook of the pipe-laying machine. The method includes receiving a signal indicating the angular position of the chassis of the pipe-laying machine relative to the ground. The method includes receiving a signal indicating the position of the boom of the pipe-laying machine relative to the underframe of the pipe-laying machine. The method further includes receiving a signal indicating the position of the counterweight of the counterweight system of the pipe-laying machine relative to the underframe. The method further includes determining the lifting capacity of the pipe-laying machine based at least in part on the received signals.

[0008] Other features and aspects of the invention will become apparent from the following description and accompanying drawings. Attached Figure Description

[0009] Figure 1 This is a perspective view of an exemplary pipe-laying machine according to an embodiment of the present invention;

[0010] Figure 2 This is a schematic diagram of a system for determining the lifting capacity of a pipe-laying machine according to an embodiment of the present invention;

[0011] Figure 3A and Figure 3B These are different perspective views of the counterweight system of a pipe-laying machine according to an embodiment of the present invention;

[0012] Figure 4A and Figure 4B This is an exemplary illustration of a system for determining the lifting capacity of a pipe-laying machine according to an embodiment of the present invention; and

[0013] Figure 5 This is a flowchart illustrating a method for determining the lifting capacity of a pipe-laying machine according to an embodiment of the present invention. Detailed Implementation

[0014] In all the accompanying drawings, the same reference numerals should be used as much as possible to denote the same or similar parts. Reference Figure 1 The image shows a perspective view of an exemplary pipe-laying machine 100. During pipe-laying operations, the pipe-laying machine 100 can be used to lift and / or lower loads, such as conduit sections, pipe sections, culvert sections, drainage sections, etc. The pipe-laying machine 100 includes a chassis 102. The chassis 102 defines a central axis X-X' of the pipe-laying machine 100. The chassis 102 supports one or more components of the pipe-laying machine 100. The pipe-laying machine 100 includes a base frame 104 operatively coupled to the chassis 102. The base frame 104 supports the pipe-laying machine 100 on a ground 106.

[0015] The underframe 104 includes a set of track roller frames, such as a first track roller frame 108 and a second track roller frame 110. The first track roller frame 108 is arranged on a first side 112 of the pipe-laying machine 100 relative to the central axis X-X'. The second track roller frame 110 is arranged on a second side 114 of the pipe-laying machine 100 relative to the central axis X-X'. The first track roller frame 108 includes a first track 116, and the second track roller frame 110 includes a second track 118. Each of the first track 116 and the second track 118 supports the pipe-laying machine 100 on the ground 106 and provides mobility for the pipe-laying machine 100. Additionally, depending on application requirements, each of the first track roller frame 108 and the second track roller frame 110 may include additional components (not shown in the figures), such as drive sprockets, one or more idler pulleys, one or more rollers, etc.

[0016] The pipelaying machine 100 includes a housing 120 mounted on a chassis 102. The housing 120 houses the power source (not shown) of the pipelaying machine 100, such as an engine, battery, etc. This power source provides power to the pipelaying machine 100 according to operational and mobility requirements. The pipelaying machine 100 also includes a cab 122 mounted on the chassis 102. The cab 122 includes various control devices (not shown), such as steering mechanisms, joysticks, operator consoles, operator seats, levers, pedals, buttons, switches, knobs, etc. These control devices are adapted to control the pipelaying machine 100 on the ground 106 during pipelaying operations. Additionally, the pipelaying machine 100 may include one or more components and / or systems (not shown) based on application requirements, such as a propulsion system, drivetrain, hydraulic system, fuel control system, engine control system, air delivery system, lubrication system, cooling system, drive control system, machine control system, etc.

[0017] The pipe-laying machine 100 further includes a boom assembly 124. The boom assembly 124 is arranged on a first side 112 of the pipe-laying machine 100. The boom assembly 124 is operatively connected to the base frame 104 and the chassis 102. The boom assembly 124 is adapted to raise and lower the load during pipe-laying operations. The boom assembly 124 includes a boom member 126. In the illustrated embodiment, the boom member 126 includes two leg sections, such as a first leg section 128 and a second leg section 130. Thus, in the illustrated embodiment, the boom member 126 has a generally elongated and triangular configuration. In other embodiments, the boom member 126 may include one or more leg sections depending on application requirements.

[0018] The boom assembly 126 includes a first end 132 and a second end 134. The second end 134 is arranged opposite the first end 132. The first end 132 is removably and hingedly coupled to a first track roller frame 108 of the pipe-laying machine 100. The boom assembly 124 includes a first boom block 136. The first boom block 136 is removably and hingedly connected to the second end 134 of the boom assembly 126. The boom assembly 124 includes a second boom block 138, which is removably and hingedly coupled to the chassis 102 of the pipe-laying machine 100. The second boom block 138 is operatively coupled to the first boom block 136 using at least one first cable 140. The first cable 140 is further operatively coupled to a block winch (not shown) arranged on the chassis 102. Therefore, based on the operation of the block winch, the first cable 140 can be retracted or extended to raise or lower the second end 134 of the boom member 126 relative to the ground 106, respectively.

[0019] The boom assembly 124 includes a first hook block 142 removably and hingedly connected to a second end 134 of the boom member 126. The first hook block 142 is arranged opposite the first boom block 136 at the second end 134 of the boom member 126. The boom assembly 124 includes a second hook block 144 having a hook 146. The second hook block 144 is operatively connected to the first hook block 142 using at least one second cable 148. The second cable 148 is further operatively connected to a hook winch (not shown) arranged on a chassis 102. Thus, based on the operation of the hook winch, the second cable 148 can be retracted or extended to raise or lower the second hook block 144 and the hook 146 relative to the ground 106, respectively.

[0020] refer to Figure 1 , Figure 3A and Figure 3B The pipe-laying machine 100 also includes a counterweight system 150. The counterweight system 150 is arranged on a second side 114 of the pipe-laying machine 100. The counterweight system 150 includes one or more counterweights 152 arranged on a counterweight frame 154. The counterweight frame 154 is movably connected to the pipe-laying machine 100 using a set of arms, such as lower arms 156, 158 and upper arms 160, 302. More specifically, each of the lower arms 156, 158 is movably connected to a second track roller frame 110 and each of the counterweight frames 154. Furthermore, each of the upper arms 160, 302 is movably connected to a chassis 102 and each of the counterweight frames 154. Additionally, the counterweight system 150 includes one or more actuators, such as hydraulic cylinders 162, 304, operably connected between the chassis 102 and the counterweight frame 154. Based on the operation of hydraulic cylinders 162 and 304, counterweight frame 154 and counterweight 152 are adapted to be in the retracted position relative to the chassis 102 of pipe-laying machine 100. Figure 1 and Figure 3A (as shown) and extension positions ( Figure 3B (shown in the middle section) moves between. Similarly, based on the position of the counterweight 152, the counterweight system 150 is adapted to provide the pipe-laying machine 100 with variable load lifting capacity.

[0021] This invention relates to a system 200 for determining the lifting capacity of a pipe-laying machine 100. (Reference) Figure 2 A schematic diagram of system 200 is shown. System 200 includes a load sensor 202. The load sensor 202 is arranged in association with a hook 146 of the pipe-laying machine 100. For example, in one embodiment, the load sensor 202 may be arranged on the hook 146. In another embodiment, the load sensor 202 may be arranged on a second hook block 144. In yet another embodiment, the load sensor 202 may be arranged on a first hook block 142.

[0022] In another embodiment, the load sensor 202 may be arranged on the first boom block 136. In another embodiment, the load sensor 202 may be arranged on the second boom block 138. In yet another embodiment, the load sensor 202 may be arranged on the block winch, and so on. The load sensor 202 can be any load sensor based on application requirements, such as a strain gauge load sensor, a piezoelectric load sensor, a pneumatic load sensor, a hydraulic load sensor, etc. The load sensor 202 is configured to generate a signal indicating the load suspended from the hook 146.

[0023] System 200 includes an angle sensor 204. The angle sensor 204 is disposed on the chassis 102 of the pipe-laying machine 100. The angle sensor 204 can be any orientation sensor based on application requirements, such as an accelerometer, gyroscope, magnetometer, inertial measurement unit (IMU) sensor, etc. The angle sensor 204 is configured to generate a signal indicating the angular position of the chassis 102 relative to the ground 106. More specifically, the angle sensor 204 is configured to generate a signal indicating the orientation of the pipe-laying machine 100 relative to the ground 106, such as machine roll, machine pitch, etc.

[0024] System 200 includes a boom position sensor 206. The boom position sensor 206 is arranged in association with a boom assembly 126 of the pipe-laying machine 100. In one embodiment, the boom position sensor 206 may be arranged on the boom assembly 126. In another embodiment, the boom position sensor 206 may be arranged on the chassis 102 and associated with the boom assembly 126. The boom position sensor 206 can be any linear or angular position sensor based on application requirements, such as a capacitive position sensor, a resistive position sensor, an inductive position sensor, a magnetic position sensor, an ultrasonic position sensor, a proximity sensor, an inertial measurement unit (IMU) sensor, etc. The boom position sensor 206 is configured to generate a signal indicating the position of the boom relative to the underframe 104 of the pipe-laying machine 100, such as angular position, boom overhang, etc.

[0025] System 200 also includes a counterweight position sensor 208. The counterweight position sensor 208 is arranged in association with the counterweight system 150 of the pipe-laying machine 100. In one embodiment, as... Figure 3A and 3B As shown, the counterweight position sensor 208 can be a rotation angle sensor 306, 307. In this case, the counterweight position sensor 208 can be arranged on a rotary joint associated with one of the lower arms 156, 158 or the upper arms 160, 302 of the counterweight system 150. For example, in one embodiment, refer to... Figure 3A The rotation angle sensor 306 can be arranged on the upper rotary joint 308 of the counterweight system 150. In another embodiment, refer to Figure 3B The rotation angle sensor 307 can be arranged on the lower rotary joint 310 of the counterweight system 150.

[0026] In another embodiment, the counterweight position sensor 208 may be a cylinder position sensor (not shown). In this case, the counterweight position sensor 208 may be arranged in association with one or more of the hydraulic cylinders 162, 304 associated with the counterweight system 150. Thus, the cylinder position sensor can generate a signal indicating the position of the corresponding hydraulic cylinder. The position of the corresponding hydraulic cylinder can further indicate the position of the counterweight 152 relative to the base frame 104. In another embodiment, the counterweight position sensor 208 may be an inertial measurement unit (IMU) sensor. In this case, the counterweight position sensor 208 may be arranged on the counterweight frame 154 of the counterweight system 150. Similarly, it should be noted that the counterweight position sensor 208 may be any position sensor configured to generate a signal indicating the position of the counterweight 152 relative to the base frame 104 (e.g., angular position, counterweight overhang, etc.).

[0027] System 200 also includes controller 210. Controller 210 can be any control unit configured to perform various functions of system 200. In one embodiment, controller 210 can be a dedicated control unit configured to perform functions related to system 200. In another embodiment, controller 210 can be a machine control unit (MCU) associated with pipelaying machine 100, an engine control unit (ECU) associated with engine, etc., configured to perform functions related to system 200.

[0028] Controller 210 is communicatively coupled to each of the load sensor 202, angle sensor 204, boom position sensor 206, and counterweight position sensor 208. Therefore, controller 210 is configured to receive signals from each of the load sensor 202, angle sensor 204, boom position sensor 206, and counterweight position sensor 208. More specifically, controller 210 is configured to receive from load sensor 202 a signal indicating the load suspended from hook 146. Controller 210 is configured to receive from angle sensor 204 a signal indicating the angular position of chassis 102 relative to ground 106. Controller 210 is also configured to receive from boom position sensor 206 a signal indicating the position of boom member 126 relative to base frame 104. Controller 210 is further configured to receive from counterweight position sensor 208 a signal indicating the position of counterweight 152 relative to base frame 104.

[0029] Based on the received signals, controller 210 is also configured to determine the lifting capacity of pipe-laying machine 100 based at least in part on signals received from each of the load sensor 202, angle sensor 204, boom position sensor 206, and counterweight position sensor 208. In one embodiment, controller 210 may be configured to determine the lifting capacity of pipe-laying machine 100 based on a pre-calibration dataset (not shown). The pre-calibration dataset may be stored in a database (not shown) communicatively coupled to controller 210 or its internal memory (not shown).

[0030] In one embodiment, the pre-calibration dataset may include a lookup table. In another embodiment, the pre-calibration dataset may include a reference graph. The lookup table or reference graph may include various values ​​of lifting capacity corresponding to different values ​​of each load suspended from hook 146, the angular position of chassis 102, the position of boom member 126, and the position of counterweight 152. In this case, controller 210 may look up or reference the value of lifting capacity based on the actual value of each load suspended from hook 146, the angular position of chassis 102, the position of boom member 126, and the position of counterweight 152.

[0031] In another embodiment, controller 210 may be configured to determine the lifting capacity of pipe-laying machine 100 based on a predetermined relationship. This predetermined relationship may be stored in a database or in the internal memory of controller 210. The predetermined relationship may be a mathematical expression or formula relating the lifting capacity to each load suspended from hook 146, the angular position of chassis 102, the position of boom member 126, and the position of counterweight 152. In other embodiments, the predetermined relationship may be any other predetermined mathematical equation, relationship, model, or algorithm used to determine the lifting capacity of pipe-laying machine 100. For example, the predetermined relationship may be a multinomial regression model, a physics-based model, a neural network model, any other model or algorithm, or a combination thereof.

[0032] More specifically, controller 210 is configured to determine the lifting capacity of pipelaying machine 100 based on the position of its center of gravity. The position of the center of gravity of pipelaying machine 100 is based at least in part on the load suspended from hook 146, the angular position of chassis 102, the position of boom member 126, and the position of counterweight 152. For example, based on each of the load suspended from hook 146, the angular position of chassis 102, the position of boom member 126, and the position of counterweight 152, the position of the center of gravity of pipelaying machine 100 can vary about the central axis X-X' between the first side 112 and the second side 114 of pipelaying machine 100.

[0033] Accordingly, if the center of gravity can extend beyond a threshold distance relative to the central axis X-X' of the pipe-laying machine 100, the pipe-laying machine 100 can rotate around the rotation point. For example, when the total load on the first side 112 can exceed the total load on the second side 114 of the pipe-laying machine 100, the center of gravity can extend towards the first side 112 of the pipe-laying machine 100 and away from the central axis X-X' in the direction "D". When the center of gravity can extend beyond the threshold distance relative to the central axis X-X' on the first side 112 of the pipe-laying machine 100 in the direction "D", the pipe-laying machine 100 can rotate around the first track 116, as indicated by arrow "T".

[0034] Controller 210 is also configured to provide the determined lifting capability to an operator (not shown). Accordingly, controller 210 can be communicatively coupled to operator interface 212 to provide the determined lifting capability to the operator. (See reference...) Figure 4A and Figure 4BExemplary displays 402 and 404 of the operator interface 212 are shown. The operator interface 212 can be a display screen based on application requirements, such as a light-emitting diode (LED) screen, a liquid crystal display (LCD) screen, a touchscreen, etc. In the illustrated embodiment, the controller 210 provides the determined lifting capability to the operator using visual cues through the operator interface 212, as shown in box 406. Furthermore, the controller 210 can provide the determined lifting capability to the operator through the operator interface 212 in the form of percentage values, graphical representations, and / or combinations thereof.

[0035] Additionally, controller 210 is configured to provide the operator with the load suspended from hook 146 via operator interface 212, as shown in box 408. Controller 210 is also configured to provide the operator with the angular position of chassis 102 relative to ground 106 via operator interface 212, as shown in box 410. Controller 210 is further configured to provide the operator with the position of boom member 126 relative to base frame 104 via operator interface 212, as shown in box 412. Controller 210 is also configured to provide the operator with the position of counterweight 152 relative to base frame 104 via operator interface 212, as shown in box 414.

[0036] In such Figure 4A In the illustrated configuration, when the machine tilt is 0 degrees (°) (as shown in box 410), the machine pitch is 0 degrees (as shown in box 410), the boom extension is 12 feet (ft.) (as shown in box 412), the load on hook 146 is 45,000 pounds (lbs.) (as shown in box 408), and the counterweight 152 is in a fully extended or 100% position (as shown in box 414), the lifting capacity of pipelaying machine 100 can be approximately 66% (as shown in box 406). In this configuration, the maximum lifting capacity of pipelaying machine 100 can be approximately 68,180 lbs., and can be indicated to the operator via box 416.

[0037] In another case, such as Figure 4B As shown, when the machine rolls at 0°, the machine pitches at 0°, the boom extension is 12 ft, the load on hook 146 is 45,000 lbs, and the counterweight 152 is in a fully retracted or 0% position, the lifting capacity of the pipelaying machine 100 can be approximately 80%. In this case, the maximum lifting capacity of the pipelaying machine 100 can be approximately 56,250 lbs. Therefore, based on the position of counterweight 152 varying between 100% and 0%, the lifting capacity of the pipelaying machine 100 can vary between approximately 66% and 80%, respectively. Thus, when the lifting capacity of the pipelaying machine 100 reaches 100%, the pipelaying machine 100 can rotate around the first track 116.

[0038] In the accompanying drawings, each of the following parameters—machine roll, machine pitch, boom extension, load on hook 146, and maximum lifting capacity of pipe-laying machine 100—is represented numerically. Furthermore, the position of counterweight 152 and each of the following parameters—the lifting capacity of pipe-laying machine 100—are indicated by percentage values ​​and graphical representations. In other embodiments, each of the following parameters—machine roll, machine pitch, boom extension, load on hook 146, maximum lifting capacity of pipe-laying machine 100, position of counterweight 152, and lifting capacity of pipe-laying machine 100—may be indicated by one or more numerical values, percentage values, and graphical representations based on application requirements.

[0039] In another embodiment, controller 210 may be configured to use auditory cues to indicate the lifting capacity of pipe-laying machine 100 to an operator. In this case, controller 210 may be communicatively coupled to an audio device, such as a speaker, to provide the auditory cues. In one embodiment, the auditory cues may be a recording. In this case, the lifting capacity of pipe-laying machine 100 may be indicated via an audio device in numerical or percentage terms. In another embodiment, the auditory cues may be a horn or a buzzer. In this case, various buzzer patterns, such as intermediate buzzers, short buzzers, long buzzers, continuous buzzers, etc., may be used to indicate the lifting capacity of pipe-laying machine 100 via an audio device. In some embodiments, controller 210 may be configured to use a combination of visual and auditory cues to indicate the lifting capacity of pipe-laying machine 100 to an operator based on application requirements.

[0040] It should be noted that the values ​​for each of the following described herein—machine roll, machine pitch, boom extension, load on hook 146, maximum lifting capacity of pipelaying machine 100, position of counterweight 152, and lifting capacity of pipelaying machine 100—are merely exemplary and may vary based on application requirements. It should also be noted that the position, orientation, and layout of the data displayed on operator interface 212 are merely exemplary and may vary based on application requirements. Furthermore, it should be noted that although boom assembly 124 and system 200 are described herein with reference to pipelaying machine 100, in other embodiments, boom assembly 124 and system 200 may be used on any other lifting machine, such as a crane.

[0041] Industrial applicability

[0042] This invention relates to a method 500 for determining the lifting capacity of a pipe-laying machine 100. (See reference) Figure 5The diagram illustrates a flowchart of method 500. In step 502, controller 210 receives a signal from load sensor 202 indicating the load suspended from hook 146 of pipe-laying machine 100. In step 504, controller 210 receives a signal from angle sensor 204 indicating the angular position of chassis 102 of pipe-laying machine 100 relative to ground 106. In step 506, controller 210 receives a signal from boom position sensor 206 indicating the position of boom member 126 of pipe-laying machine 100 relative to base frame 104 of pipe-laying machine 100.

[0043] In step 508, the controller 210 receives a signal from the counterweight position sensor 208 indicating the position of the counterweight 152 of the counterweight system 150 of the pipe-laying machine 100 relative to the base frame 104. In one embodiment, the counterweight position sensor 208 may be a rotation angle sensor 306, 307. The rotation angle sensors 306, 307 may be respectively arranged on the upper rotary joint 308 or the lower rotary joint 310 of the counterweight system 150, as shown in the reference. Figure 3A and 3B As described. In another embodiment, the counterweight position sensor 208 may be a cylinder position sensor and may be arranged in association with the hydraulic cylinders 162, 304 of the counterweight system 150. In yet another embodiment, the counterweight position sensor 208 may be an IMU sensor and may be arranged on the counterweight frame 154 of the counterweight system 150.

[0044] In step 510, controller 210 determines the lifting capacity of pipe-laying machine 100 based at least in part on the received signals. In one embodiment, controller 210 may determine the lifting capacity of pipe-laying machine 100 based on a pre-calibrated dataset such as a lookup table or reference graph. In another embodiment, controller 210 may determine the lifting capacity of pipe-laying machine 100 based on predetermined relationships, such as mathematical expressions or formulas, multinomial regression models, physics-based models, neural network models, any other models or algorithms, or combinations thereof. More specifically, controller 210 determines the lifting capacity of pipe-laying machine 100 based at least in part on the load suspended from hook 146, the angular position of chassis 102, the position of boom member 126, and the position of counterweight 152, based on the center of gravity position of pipe-laying machine 100.

[0045] In one embodiment, controller 210 may provide an operator with a defined enhancement capability in one or more forms, such as numerical values, percentage values, and graphical representations, through operator interface 212, as referenced. Figure 4A and Figure 4BAs described above. In another embodiment, controller 210 can provide the operator with the lifting capacity determined by auditory instructions via an audio device. Controller 210 can also provide the operator with the load suspended from hook 146, the angular position of chassis 102, the position of boom member 126, and the position of counterweight 152 via operator interface 212, as shown in reference... Figure 4A and Figure 4B As stated above.

[0046] Additionally, in some embodiments, when the pipe-laying machine 100 can approach 100% lifting capacity, the system 200 can provide auditory and / or visual warnings to the operator of the pipe-laying machine 100 and / or other personnel working around it. The auditory warning may be a horn or buzzer with an intermittent or continuous pattern, a recorded message, etc. The visual warning may be flashing lights in the cab 122, flashing lights or symbols on the operator interface 212, etc. In some embodiments, when one or more parameters of the pipe-laying machine 100 can be changed without operator command, the system 200 can provide auditory and / or visual warnings to the operator and / or personnel working around the pipe-laying machine 100.

[0047] For example, the orientation of the pipe-laying machine 100 may change if ground 106 can yield beneath it. This change in orientation of the pipe-laying machine 100 can be indicated to the operator and / or personnel working around the pipe-laying machine 100 without operator command via auditory and / or visual warnings. In this case, the system 200 can analyze input from the angle sensor 204 to determine the undesirable change in the orientation of the pipe-laying machine 100 and thus provide auditory and / or visual warnings to the operator and / or personnel working around the pipe-laying machine 100.

[0048] In another scenario, where the load on hook 146 may change suddenly or exceed a threshold, one or more parameters of the pipe-laying machine 100, boom assembly 124, and / or counterweight system 150 may be changed without operator command. For example, in some cases, the orientation of the pipe-laying machine 100 or the position of boom assembly 126 may be changed without operator command. In another case, the first cable 140 and / or the second cable 148 may extend beyond a threshold. In yet another case, the position of counterweight 152 may be changed without operator command.

[0049] Such changes in the parameters of the pipelaying machine 100, the boom assembly 124, and / or the counterweight system 150 without operator command can be indicated to the operator and / or personnel working around the pipelaying machine 100 via auditory and / or visual warnings. In this case, the system 200 can analyze inputs from load sensors 202, angle sensors 204, boom position sensors 206, counterweight position sensors 208, etc., to determine undesirable changes in the parameters of the pipelaying machine 100, boom assembly 124, and / or counterweight system 150, and thus determine to provide auditory and / or visual warnings to the operator and / or personnel working around the pipelaying machine 100.

[0050] In some embodiments, data generated by system 200, including but not limited to the lifting capacity of pipelaying machine 100, the load suspended from hook 146, the angular position of chassis 102, the position of boom member 126, the position of counterweight 152, and undesirable variations in one or more other parameters of pipelaying machine 100, can be transmitted to other machines operating in the field. For example, data generated by system 200 can be transmitted to adjacent machines operating in the same pipelaying operation and / or in the field as pipelaying machine 100 to effectively manage load chains relative to each machine and pipelaying operation.

[0051] In some embodiments, data generated by system 200 can be transmitted to a field management system associated with the site. This field management system may be located at or away from the site. In this case, the data generated by system 200 can be processed by the field management system to effectively manage multiple pipe-laying machines operating in the pipe-laying operation. This allows the data to be used to effectively manage the load chain relative to each pipe-laying machine and pipe-laying operation.

[0052] System 200 provides a simple, effective, and cost-efficient method for informing the operator of the lifting capacity of pipelaying machine 100. In this way, system 200 provides real-time lifting capacity of pipelaying machine 100, allowing the operator to appropriately control the pipelaying machine 100, thereby reducing reliance on operator judgment. The combination of counterweight position sensor 208 with load sensor 202, angle sensor 204, and boom position sensor 206 provides improved accuracy in determining the lifting capacity of pipelaying machine 100, thereby improving performance.

[0053] Furthermore, the auditory and / or visual warnings provided by System 200 can alert operators and / or personnel working around the pipelaying machine 100 to perform corrective / appropriate actions based on ground 106 movement, pipelaying machine 100 tilting, load transfer, etc., thereby improving performance. Moreover, System 200 utilizes components already available on the pipelaying machine 100 or readily available off-the-shelf components, such as load sensor 202, angle sensor 204, boom position sensor 206, counterweight position sensor 208, controller 210, etc., thereby reducing complexity and cost. System 200 can be refurbished on any lifting machine (e.g., crane, other pipelaying machine, etc.) with minimal or no modification to existing systems, thereby improving flexibility and compatibility.

[0054] While various aspects of the invention have been specifically shown and described with reference to the foregoing embodiments, those skilled in the art will understand that various additional embodiments can be contemplated by modifications to the disclosed machines, systems, and methods without departing from the spirit and scope of the disclosure. These embodiments should be understood to fall within the scope of the invention as defined by the claims and any equivalents thereof.

Claims

1. A system for determining the lifting capacity of a pipelaying machine, the system comprising: A load sensor, arranged in association with the hook of the pipe-laying machine, is configured to generate a signal indicating the load suspended from the hook; An angle sensor is mounted on the chassis of the pipe-laying machine and is configured to generate a signal indicating the angular position of the chassis relative to the ground. A boom position sensor is arranged in association with the boom of the pipelaying machine, the boom position sensor being configured to generate a signal indicating the position of the boom relative to the underframe of the pipelaying machine; A counterweight position sensor, arranged in association with the counterweight system of the pipelaying machine, is configured to generate a signal indicating the position of the counterweight relative to the underframe; and A controller, communicatively connectable to each of the load sensor, angle sensor, boom position sensor, and counterweight position sensor, is configured to: It receives signals from each of the load sensor, angle sensor, boom position sensor, and counterweight position sensor; as well as The lifting capacity of the pipe-laying machine is determined at least in part based on signals received from each of the load sensor, angle sensor, boom position sensor, and counterweight position sensor. The controller is configured to determine the lifting capacity of the pipelaying machine based on the center of gravity position of the pipelaying machine, which is based at least in part on the load suspended from the hook, the angular position of the chassis, the position of the boom, and the position of the counterweight.

2. The system according to claim 1, wherein the counterweight position sensor is one of a rotation angle sensor, a cylinder position sensor, and an inertial measurement unit sensor.

3. The system according to claim 2, wherein: The rotation angle sensor is arranged on a rotary joint associated with the arm of the counterweight system. The cylinder position sensor is arranged to be associated with at least one hydraulic cylinder of the counterweight system, and The inertial measurement unit sensor is arranged on the frame of the counterweight system.

4. The system of claim 1, wherein the controller is further configured to provide the determined lifting capability to an operator via an operator interface.

5. The system of claim 4, wherein the controller is further configured to provide the determined boost capability to the operator via the operator interface in at least one of a percentage value and a graphical representation.

6. The system of claim 4, wherein the controller is further configured to provide the determined lifting capability to the operator via the operator interface using at least one of auditory and visual cues.

7. The system of claim 1, wherein the controller is further configured to provide at least one of the following: The load is suspended from the hook and transferred to the operator via the operator interface. The angle position of the chassis relative to the ground is determined by the operator's interface. The position of the boom relative to the base frame is determined by the operator through the operator's interface. The position of the counterweight relative to the base frame is determined through the operator interface.

8. A pipe-laying machine, comprising: Chassis; The base frame is connected to the chassis; A boom, movably connected to the base frame, the boom including a hook suspended thereon; A counterweight system is movably connected to the base frame and arranged opposite the boom; A load sensor, arranged in association with the hook, is configured to generate a signal indicating the load suspended from the hook; An angle sensor, disposed on the chassis, is configured to generate a signal indicating the angular position of the chassis relative to the ground. A boom position sensor, arranged in association with the boom, is configured to generate a signal indicating the position of the boom relative to the base frame; A counterweight position sensor, arranged in association with the counterweight system, is configured to generate a signal indicating the position of the counterweight relative to the base frame; and A controller, communicatively connectable to each of the load sensor, angle sensor, boom position sensor, and counterweight position sensor, is configured to: It receives signals from each of the load sensor, angle sensor, boom position sensor, and counterweight position sensor; as well as The lifting capacity of the pipe-laying machine is determined at least in part based on signals received from each of the load sensor, angle sensor, boom position sensor, and counterweight position sensor. The controller is configured to determine the lifting capacity of the pipelaying machine based on the center of gravity position of the pipelaying machine, which is based at least in part on the load suspended from the hook, the angular position of the chassis, the position of the boom, and the position of the counterweight.

9. The pipe-laying machine according to claim 8, wherein the counterweight position sensor is one of a rotation angle sensor, a cylinder position sensor, and an inertial measurement unit sensor.

10. The pipe-laying machine according to claim 9, wherein: The rotation angle sensor is arranged on a rotary joint associated with the arm of the counterweight system. The cylinder position sensor is arranged to be associated with at least one hydraulic cylinder of the counterweight system, and The inertial measurement unit sensor is arranged on the frame of the counterweight system.

11. The pipe-laying machine of claim 8, wherein the controller is further configured to provide the determined lifting capacity to an operator via an operator interface.

12. The pipe-laying machine of claim 11, wherein the controller is further configured to provide the determined lifting capacity to the operator via the operator interface in at least one of a percentage value and a graphical representation.

13. The pipe-laying machine of claim 11, wherein the controller is further configured to provide the determined lifting capability to the operator via the operator interface using at least one of auditory and visual instructions.

14. The pipe-laying machine of claim 8, wherein the controller is further configured to provide at least one of the following: The load is suspended from the hook and transferred to the operator via the operator interface. The angle position of the chassis relative to the ground is determined by the operator's interface. The position of the boom relative to the base frame is determined by the operator through the operator's interface. The position of the counterweight relative to the base frame is determined through the operator interface.

15. A method for determining the lifting capacity of a pipe-laying machine, the method comprising: Receive a signal indicating the load suspended from the hook of the pipelaying machine; Receive a signal indicating the angular position of the pipe-laying machine's chassis relative to the ground; Receive a signal indicating the position of the pipe-laying machine's boom relative to the pipe-laying machine's underframe; Receive a signal indicating the position of the counterweight of the pipe-laying machine's counterweight system relative to the base frame; and The lifting capacity of the pipe-laying machine is determined at least in part based on the received signals. The lifting capacity of the pipelaying machine is also determined based at least in part on the following factors: The load suspended from the hook onto the pipe-laying machine The angle position of the chassis of the pipe-laying machine relative to the ground. The position of the boom of the pipe-laying machine relative to the base frame, and The position of the counterweight of the pipe-laying machine relative to the base frame.

16. The method of claim 15, wherein a signal indicating the position of the counterweight is received from a rotation angle sensor, and wherein the rotation angle sensor is arranged on a rotary joint associated with the arm of the counterweight system.

17. The method of claim 15, further comprising providing the determined lifting capacity to the operator in at least one of a percentage value and a graphical representation.

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