Wireless lift system

Abstract

A wireless lift system includes a first lift device having a first motor and a first wireless transceiver and a second lift device having a second motor and a second wireless transceiver. The wireless lift system includes a controller in wireless communication with the first wireless transceiver and the second wireless transceiver. The controller is configured to receive a user input and determine a first operating parameter and a second operating parameter based on the user input. The controller is further configured to wirelessly provide a first control signal indicative of the first operating parameter to the first lift device and wirelessly provide a second control signal indicative of the second operating parameter to the second lift device. The first lift device operates based on the first control signal and the second lift device operates based on the second control signal.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 62 / 868,297, filed June 28, 2019, U.S. Provisional Patent Application No. 62 / 951,394, filed December 20, 2019, and U.S. Provisional Patent Application No. 62 / 965,676, filed January 24, 2020, the entire contents of all of which are incorporated herein by reference. TECHNICAL FIELD

[0003] The present application relates to wireless hoist systems and to wirelessly controlling hoist devices for moving a workpiece and other hoist systems. BACKGROUND

[0004] Hoist devices are used to lift or lower a workpiece. Hoist devices can be manually operated, electrically or pneumatically driven, and can use chains or cables to move the workpiece. SUMMARY

[0005] For complex movements, precise placement, or moving objects that are complex (e.g., in terms of weight distribution and shape), two or more hoist devices can be used to move a workpiece from one location to another. The hoist devices can be moved in coordination by multiple users to ensure that the workpiece is not damaged. However, if there is no communication between the hoist devices, errors by the users in coordinating the hoist devices can easily occur.

[0006] One embodiment provides a wireless hoist system including a first hoist device having a first motor and a first wireless transceiver and a second hoist device having a second motor and a second wireless transceiver. The first hoist device and the second hoist device are configured to be coupled to a workpiece to lift or lower the workpiece. The wireless hoist system further includes a controller in wireless communication with the first wireless transceiver of the first hoist device and the second wireless transceiver of the second hoist device. The controller is configured to receive a user input and determine a first operating parameter and a second operating parameter based on the user input. The controller is further configured to wirelessly provide a first control signal indicative of the first operating parameter to the first hoist device and wirelessly provide a second control signal indicative of the second operating parameter to the second hoist device. The first hoist device operates based on the first control signal and the second hoist device operates based on the second control signal.

[0007] In some examples, the controller communicates with the first hoist device over a first wireless channel, and wherein the controller communicates with the second hoist device over a second wireless channel.

[0008] In some examples, the system further includes a third lifting device, and the first lifting device is further configured to: determine a third operating parameter based on the first operating parameter; and provide a third control signal indicative of the third operating parameter to the third lifting device, wherein the third lifting device operates based on the third control signal.

[0009] In some examples, the controller communicates with the first lifting device over a first wireless channel, and the first lifting device communicates with the third lifting device over a second wireless channel.

[0010] In some examples, the first lifting device further includes: a chain connectable to the workpiece to lift and lower the workpiece; a first motor coupled to the chain to release and retract the chain; a sensor to detect a chain length of the chain, the chain length of the chain being indicative of a length of the chain released from the first lifting device; and a motor driver coupled to the sensor and the motor and configured to: receive the chain length from the sensor; receive the first control signal from the controller; and drive the motor according to the first control signal and the chain length.

[0011] In some examples, the motor driver is further configured to: receive a level input from a level, the level being placed on the workpiece and the level input being indicative of an angle of the level relative to the ground, wherein the driving of the motor is further based on the level input.

[0012] In some examples, the controller is further configured to: receive a level input from a level, the level being placed on the workpiece and the level input being indicative of an angle of the level relative to the ground, wherein the determination of the first control signal and the second control signal is further based on the level input.

[0013] In some examples, the first operating parameter includes one or more selected from a group consisting of: a speed, a direction, and a chain length.

[0014] In some examples, the user input is a desired movement of the workpiece.

[0015] In some examples, the user input includes a position of the first lifting device, a position of the second lifting device, and a desired end position of the workpiece.

[0016] Another embodiment provides a wireless lift system including a first lift device having a first motor and a first wireless transceiver and a second lift device having a second motor and a second wireless transceiver. The first lift device and the second lift device are configured to couple to a workpiece to lift or lower the workpiece. The wireless lift system further includes a controller in wireless communication with the first wireless transceiver of the first lift device and the second wireless transceiver of the second lift device. The controller is configured to receive a user input and determine a first operating parameter based on the user input. The controller is further configured to wirelessly provide a first control signal indicative of the first operating parameter to the first lift device and wirelessly provide a second control signal indicative of the first operating parameter to the second lift device. The first lift device operates based on the first control signal and the second lift device operates based on the second control signal.

[0017] In some examples, the first control signal is provided to the first lift device in response to determining that a first channel associated with the first lift device is enabled and the second control signal is provided to the second lift device in response to determining that a second channel associated with the second lift device is enabled.

[0018] In some examples, the system further includes a third lift device including a third motor and a third wireless transceiver, and the third lift device is associated with a third channel. Further, in response to determining that the third channel is disabled, the controller does not provide a control signal indicative of the first operating parameter to the third lift device.

[0019] Another embodiment provides a wireless lift system including a first lift device having a first motor and a first wireless transceiver. The first lift device is configured to couple to a workpiece to lift or lower the workpiece. The wireless lift system further includes a level configured to be placed on the workpiece and to sense an angle of the level relative to a gravitational pull when the level is on the workpiece and to wirelessly output a level signal indicative of the angle. The wireless lift system further includes a controller in wireless communication with the first wireless transceiver of the first lift device and the level. The controller is configured to receive a user input and determine a first operating parameter based on the user input. The controller is further configured to receive the level signal and wirelessly provide a first control signal based on the first operating parameter and the level signal to the first lift device. The first lift device operates based on the first control signal.

[0020] In some examples, the system further includes a second lift device including a second motor and a second wireless transceiver, and the second lift device is configured to couple to the workpiece to lift or lower the workpiece. Further, the controller is configured to determine a second operating parameter based on the user input and wirelessly provide a second control signal based on the second operating parameter and the level signal to the second lift device. Further, the second lift device operates based on the second control signal.

[0021] Another embodiment provides a wireless lift system including a first lift device having a first motor and a first wireless transceiver and a second lift device having a second motor and a second wireless transceiver. The second wireless transceiver is in wireless communication with the first wireless transceiver, and the first lift device and the second lift device are configured to couple to a workpiece to lift or lower the workpiece. The wireless lift system further includes a controller in wireless communication with the first wireless transceiver of the first lift device. The controller is configured to receive a user input and determine a first operating parameter based on the user input. The controller is further configured to wirelessly provide a first control signal to the first lift device indicative of the first operating parameter. The first lift device is configured to wirelessly provide a second control signal to the second lift device, and the second control signal is based on the first control signal. The first lift device operates based on the first control signal, and the second lift device operates based on the second control signal.

[0022] In some examples, the first wireless transceiver, the second wireless transceiver, and the controller communicate via a radio frequency communication protocol. The radio frequency communication protocol uses a dual identifier, with one from a broadcast of the controller and a separate identifier for each of the first wireless transceiver and the second wireless transceiver.

[0023] In some examples, the radio frequency communication protocol initiates a pairing between the controller and the first wireless transceiver. The pairing includes broadcasting a first pairing signal from the controller to the first wireless transceiver, where the first pairing signal includes an identifier of the controller, and storing the identifier of the controller at the first wireless transceiver. The pairing further includes transmitting, by the first wireless transceiver in response to receiving the pairing signal, an identifier of the first wireless transceiver, storing the identifier of the first wireless transceiver at the controller, and generating a pairing identifier that includes at least the identifier of the controller and the identifier of the first wireless transceiver for use in performing future communications between the controller and the first wireless transceiver.

[0024] In some examples, the radio frequency communication protocol initiates a pairing between the controller and the second wireless transceiver. The pairing includes broadcasting a second pairing signal from the controller to the second wireless transceiver, where the second pairing signal includes an identifier of the controller, and storing the identifier of the controller at the second wireless transceiver. The pairing further includes transmitting, by the second wireless transceiver in response to receiving the pairing signal, an identifier of the second wireless transceiver, storing the identifier of the second wireless transceiver at the controller, and generating a pairing identifier that includes at least the identifier of the controller and the identifier of the second wireless transceiver for use in performing future communications between the controller and the second wireless transceiver.

[0025] Another embodiment includes a lift device having a power source, a motor having an output shaft, a transmission coupled to the output shaft, and a controller configured to control operation of the motor. The transmission is configured to interface with a chain and transmit rotational motion of the output shaft of the motor to the chain to release or retract the chain. The lift device is configured to raise and lower a workpiece coupled to the chain based on user command signals received at the controller.

[0026] In some examples, the lift device further includes a limit sensor configured to detect an end of the chain. The limit sensor is further configured to provide an input to the controller to stop the motor in response to detecting the end of the chain.

[0027] In some examples, the limit sensor is one or more of a mechanical limit switch, a hall sensor, a time of flight sensor, a chain speed sensor, an ultrasonic pulse transceiver, and a distance sensor.

[0028] In some examples, the limit sensor is configured to detect a change in size of one or more links of the chain indicative of the end of the chain.

[0029] In some examples, the limit sensor is configured to detect a change in color of one or more links of the chain indicative of the end of the chain.

[0030] In some examples, the limit sensor is a mechanical limit switch configured to be actuated by a feature of the chain indicative of the end of the chain.

[0031] In some examples, the lift device includes a wireless transceiver and a remote control in communication with the wireless transceiver.

[0032] In some examples, the controller is configured to determine a distance between the lift device and the remote control using a distance determination protocol. The distance determination protocol includes receiving a data packet including a time of transmission message from the remote control, determining a time of receipt at the controller of the data packet, and determining a distance between the remote control and the lift device. The distance is determined from a speed of transmission and a difference between the time of receipt and the time of transmission.

[0033] In some examples, a first internal clock of the remote control and a second internal clock of the controller are synchronized.

[0034] In some examples, the remote control includes a display device configured to display one or more parameters associated with the lift device.

[0035] In some examples, the parameters include one or more of an overload condition, an ability to complete a lift condition, a system health, an individual lift battery charge level, a remote battery charge level, a fixed load indication, and a distance between the lift device and the remote control.

[0036] In some examples, the remote control further includes an input to provide a variable speed input to the controller to control the speed of the motor.

[0037] In some examples, the controller is further configured to determine a size of a load associated with the workpiece and control the acceleration rate of the motor based on the determined size. The acceleration rate decreases as the load size increases.

[0038] In some examples, the lifting device includes a load detection device in communication with the controller.

[0039] In some examples, the load detection device is a hydraulic cylinder coupled between the lifting device and the lifting support point, the hydraulic cylinder including a pressure sensor in communication with the controller.

[0040] In some examples, the pressure sensor outputs a pressure reading indicative of a load coupled to the lifting device.

[0041] In some examples, the load detection device is a load sensor coupled between the lifting device and the lifting support point, the load sensor configured to communicate a load reading to the controller.

[0042] In some examples, the load detection device is a current sensor configured to determine a current draw of the motor, wherein the current draw is indicative of a load coupled to the lifting device.

[0043] In some examples, the load detection device is a speed sensor configured to determine a speed of the motor and communicate with the controller. The controller is configured to determine a load based on a decrease in speed of the motor from an unloaded speed.

[0044] In some examples, the lifting device further includes a load hook coupled to the first end of the chain. The load hook is configured to connect the workpiece to the chain.

[0045] In some examples, the load hook includes a safety carabiner. The safety carabiner includes an electronic sensor to determine whether the carabiner has been closed.

[0046] In some examples, the load hook includes a motion sensor configured to determine a change in balance of the workpiece as the workpiece is suspended.

[0047] In some examples, the motion sensor is one or more of an accelerometer and a gyroscope.

[0048] In some examples, the controller is further configured to determine a number of lifts remaining for the power source based on one or more parameters of the power source, a current draw during a lift operation, and a voltage drop during the lift operation.

[0049] In some examples, the controller is configured to receive the redundant data signal containing the command from a remote control in communication with the lift device.

[0050] In some examples, the controller monitors the redundant data signal from the remote control to verify accuracy of the received command.

[0051] In some examples, the controller is configured to evaluate the command received from the remote control to verify the command is within predetermined specifications.

[0052] In some examples, the remote control includes one or more dual activation inputs that require a user to perform two independent actions to transmit a command associated with the user’s actions.

[0053] In some examples, the remote control includes one or more triple activation inputs that require a user to perform three independent actions to transmit a command associated with the user’s actions.

[0054] In some examples, one of the activation inputs is a capacitive hand sensor for sensing the presence of a user’s hand.

[0055] In some examples, the lift device includes a mechanical brake configured to stop and hold the position of the workpiece during a lifting operation or a lowering operation.

[0056] In some examples, the mechanical brake is a friction brake.

[0057] In some examples, the friction brake is actuated based on a command from the controller.

[0058] In some examples, the lift device includes an electromechanical brake configured to stop and hold the position of the workpiece during a lifting operation or a lowering operation.

[0059] In some examples, the electromechanical brake is a controller based on an output from the controller.

[0060] In some examples, the lift device includes a chain lockout configured to prevent movement of the workpiece during a power outage.

[0061] In some examples, the chain lockout includes a first pawl configured to engage a first ratchet of the transmission to prevent operation of the lift device in a first direction.

[0062] In some examples, the first pawl is moved into and out of engagement with the first ratchet by one or more solenoid devices.

[0063] In some examples, the solenoid is configured to move the first pawl into engagement with the ratchet when power to the solenoid device is removed.

[0064] In some examples, the chain locking device further includes a second pawl configured to engage a second ratchet of the transmission to prevent operation of the lift device in a second direction.

[0065] In some examples, the chain locking device includes a worm gear coupled to one or more gears of the transmission to prevent movement of the load by preventing undesired movement of a primary drive gear of the transmission.

[0066] In some examples, the chain locking device is an inertia lock configured to prevent movement of the chain if a speed of the chain release exceeds a predetermined speed.

[0067] In some examples, the controller is configured to stop operation of the lift device when one or more components of the lift device receive a voice command indicating a stop.

[0068] In some examples, the controller is configured to determine a distance between the remote control and the lift device.

[0069] In some examples, the controller is configured to not accept commands from the remote control when the determined distance exceeds a predetermined threshold.

[0070] In some examples, the remote control communicates with the lift device using a line-of-sight range communication signal.

[0071] In some examples, the lift device further includes a manual lift input configured to accept a manual operation mechanism. The manual operation mechanism interfaces with one or more ratchets of the transmission to allow a user to manually raise or lower the workpiece using the manual operation mechanism.

[0072] In some examples, the controller is configured to stop operation of the lift device in response to determining an increase in current that exceeds a predetermined threshold.

[0073] In some examples, the controller is configured to stop operation of the lift device in response to determining a decrease in current that exceeds a predetermined threshold.

[0074] In some examples, the power source is a removable battery pack.

[0075] In some examples, the removable battery pack is a power tool battery pack.

[0076] Other aspects of the application will become apparent by consideration of the detailed description and accompanying drawings. BRIEF DESCRIPTION OF DRAWINGS

[0077] Figure 1 A wireless lift system according to some embodiments is shown.

[0078] Figure 2A A wireless lift system according to some embodiments is shown. Figure 1 The lifting device of the wireless lifting system.

[0079] Figure 2B According to some embodiments Figure 1 Block diagram of the lifting device of the wireless lifting system.

[0080] Figure 3 According to some embodiments Figure 1 Block diagram of the lift controller for the wireless lift system.

[0081] Figures 4A to 4C According to some embodiments, Figure 1 Example implementation of a wireless lifting system.

[0082] Figure 5 A method for mounting a workpiece according to some embodiments is shown. Figure 1 Example implementation of a wireless lifting system.

[0083] Figures 6A to 6B According to some embodiments, Figure 1 An example embodiment of a wireless lifting system, wherein Figure 1 The lifting devices are located in different installation positions.

[0084] Figure 7 According to some embodiments, Figure 1 A flow chart of a method of a wireless lifting system.

[0085] Figure 8 According to some embodiments Figure 1 Block diagram of the communication scheme of the wireless lifting system.

[0086] Figure 9 According to some embodiments Figure 8 Flowchart of the communication scheme.

[0087] Figure 10 According to some embodiments, Figure 1 A flow chart of another method of a wireless lifting system.

[0088] Figure 11 According to some embodiments, Figure 1 An example embodiment of a wireless lift system having a lift controller in communication with two or more lift devices.

[0089] Figure 12 According to some embodiments, Figure 1 Another example embodiment of a wireless lift system, wherein the wireless lift system includes controlling one or more lift devices to maintain a desired angle.

[0090] Figure 13 A block diagram for implementing the wireless lift system shown in Figure 12 is shown.

[0091] Figure 14 A control diagram for implementing the wireless lift system shown in Figure 12 is shown.

[0092] Figure 15 A flowchart of a method for operating the wireless lift system of Figures 12 to 14 is shown in accordance with some embodiments.

[0093] Figure 16 An example embodiment of the wireless lift system of Figure 1 is shown in accordance with some embodiments, in which the lift controller communicates with a single lift device.

[0094] Figure 17 A block diagram for implementing the wireless lift system shown in Figure 16 is shown.

[0095] Figure 18 A control diagram for implementing the wireless lift system shown in Figure 16 is shown.

[0096] Figure 19 A flowchart of a method for operating the wireless lift system of Figure 16 is shown in accordance with some embodiments.

[0097] Figure 20 A wireless lift system including a handheld remote control is shown in accordance with some embodiments.

[0098] Figure 21 A schematic diagram of the handheld remote control of Figure 20 is shown in accordance with some embodiments.

[0099] Figure 22 A schematic diagram of the lift device of the wireless lift system of Figure 20 is shown in accordance with some embodiments.

[0100] Figure 23 An indication system of the wireless lift system of Figure 20 is shown in accordance with some embodiments.

[0101] Figure 24 A graphical user interface of a smartphone used as the handheld remote control of Figure 20 is shown in accordance with some embodiments.

[0102] Figure 25A , Figure 25B and Figure 25CA handheld remote control according to some embodiments. Figure 20 A handheld remote control according to some embodiments.

[0103] Figure 26A A handheld remote control according to some embodiments. Figure 26B A method for calculating the distance between a controller and a lift according to some embodiments. Figure 1 A method for calculating the distance between a controller and a lift according to some embodiments. Figure 20 A method for calculating the distance between a controller and a lift according to some embodiments. A method for calculating the distance between a controller and a lift according to some embodiments.

[0104] A method for calculating the distance between a controller and a lift according to some embodiments. Figure 27A A method for calculating the distance between a controller and a lift according to some embodiments. Figure 27B A method for calculating the distance between a controller and a lift according to some embodiments. Figure 1 A method for calculating the distance between a controller and a lift according to some embodiments. Figure 20 A method for calculating the distance between a controller and a lift according to some embodiments. A method for calculating the distance between a controller and a lift according to some embodiments.

[0105] A method for calculating the distance between a controller and a lift according to some embodiments. Figure 28A A method for calculating the distance between a controller and a lift according to some embodiments. Figure 28B A method for calculating the distance between a controller and a lift according to some embodiments. Figure 28C A method for calculating the distance between a controller and a lift according to some embodiments. Figure 28D A method for calculating the distance between a controller and a lift according to some embodiments. Figure 1 A method for calculating the distance between a controller and a lift according to some embodiments. Figure 20 A method for calculating the distance between a controller and a lift according to some embodiments. A method for calculating the distance between a controller and a lift according to some embodiments.

[0106] A method for calculating the distance between a controller and a lift according to some embodiments. Figure 29A A method for calculating the distance between a controller and a lift according to some embodiments. Figure 29B A method for calculating the distance between a controller and a lift according to some embodiments. Figure 29C A method for calculating the distance between a controller and a lift according to some embodiments. A method for calculating the distance between a controller and a lift according to some embodiments.

[0107] A method for calculating the distance between a controller and a lift according to some embodiments. Figure 30 A tilt winch system according to some embodiments that can be used with a lift system of Figure 1 A tilt winch system according to some embodiments that can be used with a lift system of A tilt winch system according to some embodiments that can be used with a lift system of

[0108] A tilt winch system according to some embodiments that can be used with a lift system of Figure 31 A process for determining the last lift of a DC battery powered lift according to some embodiments. A process for determining the last lift of a DC battery powered lift according to some embodiments.

[0109] A process for determining the last lift of a DC battery powered lift according to some embodiments. Figure 32 A process for controlling the soft start function of a motor according to some embodiments. A process for controlling the soft start function of a motor according to some embodiments.

[0110] A process for controlling the soft start function of a motor according to some embodiments. Figure 33 A data graph showing the relationship between motor acceleration and load size in a lift system according to some embodiments. A data graph showing the relationship between motor acceleration and load size in a lift system according to some embodiments.

[0111] A system for determining the load size on a chain lift according to some embodiments. Figure 34 A system for determining the load size on a chain lift according to some embodiments. A system for determining the dynamic load of a lift system according to some embodiments.

[0112] A system for determining the dynamic load of a lift system according to some embodiments. Figure 35 A system for determining the dynamic load of a lift system according to some embodiments. A system for determining the dynamic load of a lift system according to some embodiments.

[0113] A system for determining the dynamic load of a lift system according to some embodiments. Figure 36An intelligent hook for use with a hoist system is shown in accordance with some embodiments.

[0114] Figure 37 A system incorporating an intelligent hook for a hoist system is shown in accordance with some embodiments. Figure 36

[0115] Figure 38 An electromechanical brake in an engaged position is shown.

[0116] Figure 39 An electromechanical brake in a disengaged position is shown.

[0117] Figure 40 A hand operated mechanism is shown that is operably coupled to a motor shaft of a hoist in a first position.

[0118] Figure 41 A hand operated mechanism is shown that is operably coupled to a motor shaft of a hoist in a second position.

[0119] Figure 42 A limit switch mechanism for a hoist is shown.

[0120] Figure 43A A limit switch mechanism for a hoist is shown in accordance with one embodiment.

[0121] Figure 43B A limit switch mechanism for a hoist is shown when a stop interacts with the limit switch mechanism. Figure 43A

[0122] Figure 44A A limit switch mechanism for a hoist is shown in accordance with another embodiment.

[0123] Figure 44B A limit switch mechanism for a hoist is shown in accordance with another embodiment.

[0124] Figure 44C A hard stop or overload clutch mechanism for a hoist is shown.

[0125] Figure 45 A hoist controller is shown that is operably coupled to a hoist via a retractable cord.

[0126] Figure 46 A user operating a hoist is shown. Figure 45

[0127] A user operating a hoist is shown in accordance with another embodiment. Figure 47

[0128] Figure 48 ​​​A power storage compartment for a lift device is shown.

[0129] Figure 49 A regenerative braking mechanism for a lift device is shown.

[0130] Figure 50 An inertia lock for a lift device according to some embodiments is shown.

[0131] Figure 51 A cam lock for a lift device according to some embodiments is shown.

[0132] Figure 52A A mechanical ratchet / clutch system for a lift device according to some embodiments is shown.

[0133] Figure 52B A bidirectional ratchet clutch system for a lift device according to some embodiments is shown.

[0134] Figure 53 A solenoid-based locking system for a lift device according to some embodiments is shown.

[0135] Figure 54 A ratchet mechanism for a lift device according to some embodiments is shown.

[0136] Figure 55 A worm gear mechanism for a lift device according to some embodiments is shown.

[0137] Figure 56 An electromechanical brake for a lift device according to some embodiments is shown.

[0138] Figure 57 A process for modifying operation of a lift device according to some embodiments is shown.

[0139] Figure 58 A lift device configured to receive voice commands according to some embodiments is shown.

[0140] Figure 59 A motion-activated lift system according to some embodiments is shown.

[0141] Figure 60 A chain controller lift system according to some embodiments is shown.

[0142] Figure 61 A modular lift device according to some embodiments is shown.

[0143] Figure 62 A remotely powered lift system according to some embodiments is shown.

[0144] Before any embodiments are explained in detail, it is to be understood that the application is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. Embodiments are capable of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and not of limitation. The use of "including," "comprising," or "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms "mounted," "connected," "supported," and "coupled" are used broadly and encompass both direct and indirect mounting, connecting, supporting, and coupling. Further, "connected" and "coupled" are not restricted to physical or mechanical connections or couplings, and can include electrical connections or couplings, whether direct or indirect. Also, as used herein, the term "and / or" means that the items listed before and after the term are either included individually or in combination.

[0145] It should be noted that the described embodiments can be implemented utilizing a plurality of hardware and software-based devices and a plurality of differently structured components. Further, as described in the subsequent paragraphs, the particular configurations shown in the drawings are intended to be exemplary embodiments and other alternative configurations are possible. Unless otherwise stated, the terms "processor," "central processing unit," and "CPU" can be used interchangeably. When the term "processor" or "central processing unit" or "CPU" is used in reference to a unit that performs a particular function, it should be understood that, unless otherwise noted, that function can be performed by a single processor or by multiple processors in any configuration arranged to perform that function, including parallel, serial, tandem, or cloud processing / cloud computing configurations.

[0146] It should be understood that, although certain drawings show hardware and software located within particular devices, these drawings are for illustrative purposes only. In some embodiments, the illustrated components can be combined or divided into separate software, firmware, and / or hardware. For example, logic and processing can be distributed among multiple electronic processors rather than located within and performed by a single electronic processor. Regardless of how they are combined or divided, hardware and software components can be located on the same computing device or can be distributed among different computing devices connected through one or more networks or other suitable communication links. DETAILED DESCRIPTION

[0147] Figure 1One example embodiment of a wireless lift system 100 is shown, which includes a plurality of lifts 110 (e.g., a first lift 110A and a second lift 110B), a lift controller 120, and a workpiece 130. The first lift 110A and the second lift 110B are mounted on a support surface 140. The support surface 140 is, for example, a ceiling, a wall, a beam, or other structure of a workroom. The first lift 110A and the second lift 110B can be individually referred to as a lift 110. The lift controller 120 is, for example, a handheld device such as a joystick controller (see Figure 20 and Figures 25A to 25C ), a smartphone (see Figure 24 ), a tablet, and the like.

[0148] The first lift 110A is connected to the workpiece 130 by a first chain 115A of the first lift 110A. The second lift 110B is connected to the workpiece 130 by a second chain 115B of the second lift 110B. The first lift 110A and the second lift 110B move the workpiece 130 by operating the first chain 115A and the second chain 115B, respectively. The first chain 115A and the second chain 115B can be individually referred to as a chain 115. The lift controller 120 can control one or more of the first lift 110A and the second lift 110B (e.g., the plurality of lifts 110) to move the workpiece 130 between different positions. Figure 1 Only one example embodiment of the wireless lift system 100 is shown. The wireless lift system 100 can include more or fewer components and can perform functions other than those explicitly disclosed herein.

[0149] Figure 2A One example embodiment of a lift 110 is shown. The lift 110 can be mounted to a support surface 140 (see Figure 1). The lift 110 includes a first hook 204 for mounting the lift 110 to a support surface, such as the support surface 140. In some embodiments, other mounting elements, such as fasteners, can be used to mount the lift 110 to the support surface 140. The lift 110 also includes a second hook 208 for connecting the lift 110 to the workpiece 130. The lift 110 releases and retracts the chain 115 to raise and lower a workpiece, such as the workpiece 130. In other embodiments, the lift 110 can be mounted to the floor or other ground support, and a pulley or other device can be coupled to the support surface 140 and coupled by the chain 115. Operation of the lift 110 releases and retracts the chain to raise and lower the workpiece through the pulley. By mounting the lift to the floor or other ground support, more convenient access to the lift is provided, allowing for maintenance without lifting or removing the lift from the support surface 140.

[0150] Figure 2B is a block diagram of one example embodiment of the lift 110. The lift 110 includes a lift electronic processor 210 (e.g., a motor driver), a lift memory 220, a lift transceiver 230 (e.g., a first wireless transceiver and a second wireless transceiver), a lift power supply 240, a lift motor 250 (e.g., a first motor and a second motor), and one or more lift sensors 260. The lift electronic processor 210 communicates with the lift memory 220, the lift transceiver 230, the lift motor 250, and the one or more lift sensors 260 over one or more control and / or data buses, such as a lift communication bus 270. Figures 2A to 2B Only one example embodiment of the lift 110 is shown. The lift 110 can include more or fewer components and can perform functions other than those explicitly described herein.

[0151] In some embodiments, the lift electronic processor 210 is implemented as a microprocessor with a separate memory (e.g., the lift memory 220). In other embodiments, the lift electronic processor 210 can be implemented as a microcontroller (which has the lift memory 220 on the same chip). In other embodiments, the lift electronic processor 210 can be implemented using multiple processors. Further, the lift electronic processor 210 can be partially or entirely implemented as, for example, a field programmable gate array (FPGA) and an application specific integrated circuit (ASIC), among others, and can not require or require modification of the lift memory 220. In the illustrated example, the lift memory 220 includes a non-transitory computer readable memory that stores commands received by and executed by the lift electronic processor 210 to perform the functions of the lift 110 described herein. The lift memory 220 can include, for example, a program storage area and a data storage area. The program storage area and the data storage area can include a combination of different types of memory (e.g., read only memory and random access memory).

[0152] The lift transceiver 230 can enable wireless communication between the lift 110 and other devices (e.g., other lifts 110, the lift controller 120, etc.). In some embodiments, the lift transceiver 230 includes a combined transmitter and receiver, while in other embodiments, the lift transceiver 230 includes separate transmitters and receivers.

[0153] The lift power source 240 can be a direct current power source (e.g., a power tool battery pack coupled with the lift 110) or can be an alternating current power source (e.g., a power cord plugged into an alternating current power outlet (e.g., a wall outlet)). In one example, the lift power source 240 is a M18 RED LITHIUM battery pack sold and marketed by Milwaukee Electric Tool Corporation. The lift power source 240 provides operating power to the lift motor 250 and other electrical components (e.g., the lift electronic processor 210, the lift transceiver 230, etc.). Electrical connections between the lift power source 240 and other components of the lift 110 are not shown to simplify the illustration. The lift motor 250 is, for example, an alternating current motor, a brushless direct current motor, a brushed motor, etc., powered by the lift power source 240. The lift motor 250 is controlled by the lift electronic processor 210 to release or retract the chain 115 from the lift 110. The lift 110 includes a transmission mechanism for connecting an output shaft of the lift motor 250 to the chain 115. One or more lift sensors 260 include, for example, a length sensor to detect an amount of chain 115 released, a tension sensor to detect tension in the chain 115, a resolver to detect motor position, a torque or current sensor to detect torque of the lift motor 250, etc.

[0154] Figure 3is a block diagram of one example implementation of the lift controller 120. The lift controller 120 includes a controller electronic processor 310, a controller memory 320, a controller transceiver 330, a user interface 340, and a power source 345. The lift controller 120 can include a housing that supports the elements of the lift controller 120 described herein (at least in Figure 1 illustrated schematically in FIG. 3). The controller electronic processor 310 is in communication with the controller memory 320, the controller transceiver 330, and the user interface 340 by one or more control and / or data buses (e.g., a controller communication bus 350). Figure 3 Only one example implementation of the lift controller 120 is shown. The lift controller 120 can include more or fewer components and can perform functions other than those explicitly described herein.

[0155] The controller electronic processor 310, the controller memory 320, and the controller transceiver 330 can be implemented similarly to the lift electronic processor 210, the lift memory 220, and the lift transceiver 230. The controller transceiver 330 can enable wireless communication between the lift controller 120 and other devices (e.g., the plurality of lift devices 110). The lift controller 120 and the plurality of lift devices 110 can communicate over, for example, a Bluetooth network, a Wi-Fi network, or the like. As described further below, the lift controller 120 and the plurality of lift devices 110 can communicate over the same channel or different channels.

[0156] The user interface 340 can include one or more input devices (e.g., buttons, triggers, joysticks, keyboards, etc.), one or more output devices (e.g., light emitting diodes (LEDs), speakers, displays, etc.), and / or one or more input / output devices (e.g., touch screen displays). The lift controller 120 can receive control inputs (e.g., user inputs) from a user through the user interface 340. For example, a user can move a joystick to control the release or retraction of the chain 115 from one or more of the lift devices 110.

[0157] The power source 345 is coupled to and powers components of the lift controller 120, including the controller electronic processor 310, the controller memory 320, the controller transceiver 330, and the user interface 340. Electrical connections between the power source 345 and other components of the lift controller 120 are not shown to simplify the illustration. In some implementations, the power source 345 is a direct current power source that includes, for example, one or more battery cells (e.g., AA, AAA, 9V) or a battery pack with one or more battery cells (e.g., a power tool battery pack or a USB power source). In one example, the power source 345 is a M12 battery pack sold and marketed by Milwaukee Electric Tool Corporation. The direct current power source increases the portability and mobility of the lift controller 120 compared to a wired alternating current power source. However, in some implementations, the power source 345 is an alternating current power circuit that receives alternating current power through an electrical cord connected to an alternating current power source (e.g., a wall outlet), converts the alternating current power to direct current power (e.g., through a rectifier or a power switching element), and outputs the direct current power.

[0158] Figures 4A to 4C Several example implementations of the wireless lift system 100 are shown. The wireless lift system 100 is used to lift or lower a workpiece 130 using a first lift device 110A and a second lift device 110B. The first chain 115A and the second chain 115B are coupled to different locations on the workpiece 130 to place the workpiece at an angle. In Figure 4A the workpiece 130 is lifted or lowered at an angle from the ground (e.g., a non-zero angle from the ground). The first lift device 110A and the second lift device 110B are controlled by the lift controller 120 to have different chain lengths to maintain the non-zero angle. In Figure 4B the workpiece 130 is lifted or lowered at a horizontal angle (e.g., 0 degrees from the ground). The first lift device 110A and the second lift device 110B are controlled by the lift controller 120 to have the same chain lengths to maintain the horizontal angle. In Figure 4C the wireless lift system 100 is used to lift or lower a workpiece 130 having an irregular shape such that the first lift device 110A and the second lift device 110B can have different chain lengths to maintain the lifting angle of the workpiece 130.

[0159] Figure 5 Another example implementation of the wireless lift system 100 is shown. The wireless lift system 100 is used to lift a workpiece 130 from a first location 510 and install the workpiece 130 at a second location 520. The first chain 115A and the second chain 115B are coupled at the same location or adjacent locations to install the workpiece 130. Specifically, the first lift device 110A and the second lift device 110B work together to move the workpiece 130 vertically and laterally to install the workpiece 130 at the second location 520.

[0160] Figures 6A to 6B Different mounting positions of the lifting devices 110 are shown. A first lifting device 110A is mounted to a first support surface 610 (e.g., a ceiling) of the workcell, and a second lifting device 110B is mounted to a second support surface 620 (e.g., a wall) of the workcell. The mounting positions of the first lifting device 110A and the second lifting device 110B can vary depending on the mounting locations 520 and obstacles in the workcell.

[0161] Figure 7 A flowchart of an example method 700 of operating the wireless lifting system 100 is shown. In the example shown, the method 700 includes receiving user input at the user interface 340 of the lifting controller 120 (at block 710). A user of the wireless lifting system 100 uses the lifting controller 120 to control the lifting devices 110. The user provides control input to the lifting controller 120 through the user interface 340. For example, the user interface 340 includes a joystick controller and the user moves the joystick controller to produce movement of the workpiece by the lifting devices 110. The user interface 340 can receive user input from the user including a plurality of operational parameters for the work to be performed by the wireless lifting system 100. The user input can include a desired movement of the workpiece 130, such as a direction of movement, a speed of movement, a starting point, an ending point, etc. of the workpiece 130. The user interface 340 can also receive as user input a position of the first lifting device 110A, a position of the second lifting device 110B, and a desired ending position of the workpiece 130.

[0162] The method 700 includes determining first and second operation parameters based on user input using the controller electronic processor 310 (at block 720). The first operation parameter corresponds to the first lifting device 110A, and the second operation parameter corresponds to the second lifting device 110B. The controller electronic processor 310 receives user input, such as desired movement of the workpiece, positions of the lifting devices 110 and the workpiece, and determines operation parameters of the first lifting device 110A and the second lifting device 110B based on the user input. For example, the controller electronic processor 310 receives desired movement of the workpiece as user input and determines a direction and / or speed and / or chain length of movement of the first chain 115A of the first lifting device 110A and a direction and / or speed and / or chain length of movement of the second chain 115B of the second lifting device 110B. The direction and / or speed and / or chain length of movement of the first chain 115A corresponds to the first operation parameter, and the direction and / or speed and / or chain length of movement of the second chain 115B corresponds to the second operation parameter. In another example, the controller electronic processor 310 receives respective positions of the first and second lifting devices 110A and 110B and a desired end position of the workpiece as user input and determines a direction and / or speed and / or chain length of movement of the first chain 115A of the first lifting device 110A and a direction and / or speed and / or chain length of movement of the second chain 115B of the second lifting device 110B. In this example, the controller electronic processor 310 can also use respective chain lengths of the first and second chains 115A and 115B from the first and second lifting devices 110A and 110B to determine the first and second operation parameters. For example, the controller electronic processor 310 can determine an initial position 260 of the workpiece based on positions of the lifting devices 110 (which can be input at a setup stage) and respective chain lengths (which can be determined using respective sensors). The controller electronic processor 310 finds a distance and direction between the initial position determined above and the desired end position received from the user input. The positions of the lifting devices 110 and the initial position of the workpiece can be provided or determined, for example, relative to one common reference point (e.g., a point on the floor) or multiple reference points with known relative positions. The controller electronic processor 310 uses the distance and direction to calculate the direction and / or speed and / or chain length of movement of the first and second chains 115A and 115B. For example, the positions can be represented in one of various formats, such as using a Cartesian coordinate system or another coordinate system. The direction and chain length required for each lifting device 110 to move the workpiece from the initial position to the end position can then be calculated, for example, by determining coordinate differences of the initial and end positions relative to the positions of the lifting devices 110.

[0163] The method 700 includes wirelessly providing, using the controller electronic processor 310, a first control signal indicative of a first operating parameter to the first lift device 110A (at block 730). The controller electronic processor 310 provides the control signal corresponding to the first operating parameter to the first lift device 110A via the controller transceiver 330. The first lift device 110A receives the first control signal through the lift transceiver 230 (i.e., the first wireless transceiver). The first lift device 110A operates based on the first control signal. That is, the first lift device 110A controls the lift motor 250 (i.e., the first motor) of the first lift device 110A based on the first control signal. For example, the lift electronic processor 210 of the first lift device 110A controls the lift motor 250 of the first lift device 110A to match the direction, chain length, and / or speed indicated by the first control signal.

[0164] The method 700 also includes wirelessly providing, using the controller electronic processor 310, a second control signal indicative of a second operating parameter to the second lift device 110B (at block 740). The controller electronic processor 310 provides the control signal corresponding to the second operating parameter to the second lift device 110B through the controller transceiver 330. The second lift device 110B receives the second control signal through the lift transceiver 230 (i.e., the second wireless transceiver). The second lift device 110B operates based on the second control signal. That is, the second lift device 110B controls the lift motor 250 (i.e., the second motor) of the second lift device 110B based on the second control signal. For example, the lift electronic processor 210 of the second lift device 110B controls the lift motor 250 of the second lift device 110B to match the direction, chain length, and / or speed indicated by the second control signal.

[0165] In some embodiments, the method 700 can include determining the first operating parameter (rather than both the first operating parameter and the second operating parameter) based on user input at block 720. This embodiment can be suitable, for example, where the first lift device 110A and the second lift device 110B include similar operations for moving a workpiece as shown in Figure 1 and Figures 4A to 4C In these embodiments, the method 700 further includes wirelessly providing the first control signal indicative of the first operating parameter to the first lift device 110A (at block 730) and wirelessly providing the second control signal indicative of the first operating parameter to the second lift device 110B (at block 740).

[0166] In some embodiments, the user may continuously provide the signal until the workpiece 130 reaches the desired end position. For example, the user may move a joystick controller until the workpiece 130 reaches the desired end position. In these embodiments, the method 700 repeats to continuously provide the first and second control signals (which may vary over time) to the first and second lifting devices 110A, 110B until the user ceases providing the user input (e.g., releases the joystick). In some embodiments, the user may provide the desired end position along with other inputs, and the method 700 may continuously provide the first and second control signals until the desired end position is reached. Alternatively, the method 700 may provide the first and second control signals once to the first and second lifting devices 110A, 110B, and the first and second lifting devices 110A, 110B operate until the workpiece 130 is in the desired position.

[0167] like Figure 8 As shown, lift controller 120 communicates with different lift devices 110 via different wireless communication channels 810. For example, lift controller 120 communicates with first lift device 110A via first channel 810A (i.e., first wireless channel), communicates with second lift device 110B via second channel 810B (i.e., second wireless channel), and so on. Communicating with different lift devices 110 via different communication channels 810 prevents interference between the different lift devices. Depending on the implementation of wireless lift system 100, a user can selectively activate channels 810. For example, for a certain time period or operation, a user can activate only first channel 810A to enable communication with first lift device 110A and deactivate all other channels 810. A wireless network can operate within a certain radio signal frequency bandwidth. That is, a wireless network includes a minimum radio frequency and a maximum radio frequency, and the wireless network utilizes a frequency band between the minimum and maximum radio frequencies to transmit and receive radio signals. The wireless bandwidth can be further divided into multiple channels, for example, by dividing the bandwidth into smaller frequency intervals. For example, a 20 MHz wireless frequency band might be divided into several 5 GHz channels. A host device can communicate with multiple other devices over a single channel or across the entire wireless network. However, communicating over a single channel or across the entire wireless network may result in interference between different communication paths (i.e., the communication path between the host device and the guest device) or may require special addressing to avoid interference. By communicating with different devices on different channels, interference and special addressing can be avoided.

[0168] Figure 9A flowchart of a method 900 of communication between the lift controller 120 and multiple lift devices 110 is shown. In the example shown, the method 900 includes reading, using the controller electronic processor 310, a direction and a speed input by a user through the user interface 340 (at block 910). The user can input a desired direction and speed for moving the workpiece 130 using the user interface 340. The method 900 also includes determining, using the controller electronic processor 310, whether the first channel 810A is enabled (at block 920). When the first channel 810A is enabled, the method 900 includes providing, using the controller electronic processor 310, the direction and speed information to the first lift device 110A via the controller transceiver 330 and the first channel 810A (at block 930). That is, responsive to determining that the first channel 810A associated with the first lift device 110A is enabled, a first control signal is provided to the first lift device 110A. The method 900 similarly includes determining whether the other channels 810 are enabled (at blocks 935 and 945) and providing the direction and speed information to the respective lift devices 110 when the respective channels 810 are enabled (at blocks 940 and 950). Responsive to determining that the second channel 810B associated with the second lift device 110B is enabled, a second control signal is provided to the second lift device 110B. When a channel 810 is disabled (not enabled), the lift controller 120 does not provide direction and speed information to the lift device 110 associated with the disabled channel. That is, the lift controller 120 provides a control signal indicative of the first operating parameter to the third lift device 110 responsive to determining that the third channel is disabled.

[0169] Figures 10 and 11 An example implementation of a wireless lift system 100 is shown in which two or more lift devices 110 are controlled by a lift controller 120 to install a workpiece 130. In the example shown, the lift controller 120 is in wireless communication with the first lift device 110A through a first wireless communication channel 810A and with the second lift device 110B through a second wireless communication channel 810B.

[0170] Figure 10 A method 1000 for a wireless lift system 100 is shown. In the example shown, the method 1000 includes receiving, using the controller electronic processor 310, a first position of the first lift device 110A (at block 1010). The method 1000 also includes receiving, using the controller electronic processor 310, a second position of the second lift device 110B (at block 1020). The user can input the first position data and the second position data using the user interface 340. The positions can be represented in various coordinate system formats (e.g., Cartesian coordinate system) using a common reference point or multiple reference points with known or indicated relative positions.

[0171] The method 1000 also includes connecting the first lifting device 110A to the workpiece 130 (at block 1030) and connecting the second lifting device 110B to the workpiece 130 (at block 1040). The user can use the second hooks of the first and second lifting devices 110A and 110B, respectively, to connect the first and second lifting devices 110A and 110B to the workpiece 130.

[0172] The method 1000 includes calculating the workpiece position using the controller electronic processor 310 based on the first position, the second position, and the chain length information (at block 1050). As described above, the controller electronic processor 310 receives the first position information and the second position information from the user through the user interface 340. In addition, the lifting controller 120 communicates with the first lifting device 110A to determine the chain length that the first chain 115A is released (determined by the first lifting device 100A based on the sensor 260) and communicates with the second lifting device 110B to determine the chain length that the second chain 115B is released (determined by the first lifting device 100A based on the sensor 260). The controller electronic processor 310 determines the workpiece position based on the position information of the lifting devices 110 and the corresponding chain lengths.

[0173] The method 1000 also includes receiving a desired workpiece position using the controller electronic processor 310 (at block 1060). The user can input the desired workpiece position using the user interface 340. For example, the position can be specified using the same coordinate system used to specify the first and second lifting positions. Based on the workpiece position and the desired workpiece position, the lifting controller 120 can automatically provide control signals to the first and second lifting devices 110A and 110B (at block 1070). Figure 11 An example technique to implement block 1070 is shown, in which the lifting controller 120 provides the user desired workpiece position to the first and second lifting devices 110A and 110B.

[0174] Reference Figure 11Further explanation of the control of the first and second lifting devices 110A, 110B based on the first and second control signals. The first lifting device 110A includes a proportional-integral-derivative (PID) controller 1110, for example, implemented by the lifting electronic processor 210 of the first lifting device 110A. The PID controller 1110 or the lifting electronic processor 210 forms a motor drive of the first lifting device 110A. The PID controller 1110 is coupled to a length / speed sensor 1120 (e.g., a sensor for detecting chain length). The PID controller 1110 receives sensor data from the length / speed sensor 1120. For example, the PID controller 1110 receives chain length information from the length / speed sensor 1120, which indicates an amount of chain released from the first lifting device 110A. The PID controller 1110 also receives the first control signal from the lift controller 120. The PID controller 1110 controls a motor 1130 (e.g., the motor 250 of the first lifting device 110A) to install the workpiece 130 based on the first control signal and the chain length information.

[0175] Similarly, the second lifting device 110B includes a proportional-integral-derivative (PID) controller 1140, for example, implemented by the lifting electronic processor 210 of the second lifting device 110B. The PID controller 1140 or the lifting electronic processor 210 forms a motor drive of the second lifting device 110B. The PID controller 1140 is coupled to a length / speed sensor 1150 (e.g., a sensor for detecting chain length). The PID controller 1140 receives sensor data from the length / speed sensor 1150. For example, the PID controller 1140 receives chain length information from the length / speed sensor 1150, which indicates an amount of chain released from the second lifting device 110B. The PID controller 1140 also receives the second control signal from the lift controller 120. The PID controller 1140 controls a motor 1160 (e.g., the motor 250 of the second lifting device 110B) to install the workpiece 130 based on the second control signal and the chain length information.

[0176] Figure 12 、 Figure 13 and Figure 14One example embodiment of a wireless lift system 100 is shown in which one or more lifts 110 are controlled by a lift controller 120 to install a workpiece 130. The wireless lift system 100 additionally includes a level sensor 1200 mounted to the workpiece 130 to measure the angle or orientation of the workpiece 130 relative to the force of gravity (or ground). In the example shown, the lift controller 120 wirelessly communicates with the first lift 110A over a first wireless communication channel 810A, with the second lift 110B over a second wireless communication channel 810B, and with the level sensor 1200 over a third wireless communication channel 810C. The level sensor 1200 can include an electronic processor, memory, and a transceiver (e.g., each similar to the similarly named components of the lift controller 120), as well as a sensor (e.g., an accelerometer, gyroscope, etc.) configured to produce level data and communicate with the electronic processor. The electronic processor of the level sensor 1200 can receive level data from the level sensor and transmit the level data to other devices (e.g., the lift controller 120 or the lifts 110) via the transceiver of the level sensor 1200.

[0177] Figure 15 A flowchart of one example method 1500 of operating the wireless lift system 100 is shown. Figures 12 to 14 In the example shown, the method 1500 includes receiving user input at the user interface 340 of the lift controller 120 (at block 1510). A user of the wireless lift system 100 uses the lift controller 120 to control the lifts 110. The user provides control input to the lift controller 120 through the user interface 340. For example, the user interface 340 includes a joystick controller and the user moves the joystick controller to produce movement of the workpiece by the lifts 110. The user interface 340 can receive user input from the user including a plurality of operational parameters for the wireless lift system 100 to perform a job. The user input can include a desired movement of the workpiece 130, such as a direction of movement, a speed of movement, a starting point, an ending point, etc. of the workpiece 130. The user input can also include a position of the first lift 110A, a desired angle of the level 1200, a desired ending point position of the workpiece 130, etc.

[0178] The method 1500 includes determining, using the controller electronic processor 310, a first operation parameter based on user input (at block 1520). The first operation parameter can correspond to operation of the first lifting device 110A and / or the second lifting device 110B. The controller electronic processor 310 receives user input, such as desired movement of the workpiece, desired angle of the level 1200, position of the lifting device 110 and the workpiece, and determines operation parameters of the first lifting device 110A and / or the second lifting device 110B based on the user input. For example, the controller electronic processor 310 receives desired motion of the workpiece as user input and determines direction and / or speed and / or chain length of the first chain 115A of the first lifting device 110A and the second chain 115B of the second lifting device 110B. The direction and / or speed and / or chain length of the first chain 115A and the second chain 115B correspond to the first operation parameter. In another example, the controller electronic processor 310 receives respective positions of the first lifting device 110A and the second lifting device 110B and a desired end position of the workpiece as user input and determines direction and / or speed and / or chain length of the first chain 115A of the first lifting device 110A and the second chain 115B of the second lifting device 110B. In this example, the controller electronic processor 310 can also use respective chain lengths of the first chain 115A and the second chain 115B from the first lifting device 110A and the second lifting device 110B to determine the first operation parameter. For example, the controller electronic processor 310 can determine an initial position of the workpiece based on the positions of the lifting device 110 and the respective chain lengths. The controller electronic processor 310 finds a distance and direction between the initial position determined above and the desired end position received from the user input. The controller electronic processor 310 uses the distance and direction to calculate the direction and / or speed and / or chain length of the first chain 115A and the second chain 115B.

[0179] The method 1500 includes receiving a level signal from the level sensor 1200 (at block 1530). As described above, the level sensor 1200 measures the angle of the level sensor relative to gravity and continuously provides the measured angle to the lift controller 120. The method 1500 includes wirelessly providing, using the controller electronic processor 310, a first control signal indicative of a first operating parameter and the level signal to the first lift device 110A (at block 1540). The controller electronic processor 310 provides the control signal corresponding to the first operating parameter and the level signal to the first lift device 110A through the controller transceiver 330. The first lift device 110A receives the first control signal through the lift transceiver 230 (i.e., the first wireless transceiver). The first lift device 110A operates based on the first control signal. That is, the first lift device 110A controls the lift motor 250 (i.e., the first motor) of the first lift device 110A based on the first control signal. For example, the lift electronic processor 210 of the first lift device 110A controls the lift motor 250 of the first lift device 110A to match the direction, chain length, and / or speed indicated by the first control signal. The first control signal can take into account a desired level angle provided by a user through the user input and indicate the direction, chain length, and / or speed to maintain the user-desired level angle during operation. The method 1500 can repeat until the workpiece 130 is installed at the desired location. Further, in some embodiments, in addition to providing the first control signal indicative of the first operating parameter and the level signal to the first lift device, in block 1540, the controller 120 can provide a second control signal indicative of a second operating parameter and the level signal to the second lift device 110B using similar operating principles.

[0180] Figure 14 Another control diagram of the wireless lift system 100 that can be used to implement the method 1500, as well as additional methods, is shown. Figure 14The diagram includes determining desired parameter information (e.g., a desired angle of the workpiece 130 and a desired operating speed) using the controller electronic processor 310. The controller electronic processor 310 also provides control signals indicating the desired parameter information to the first lifting device 110A and the second lifting device 110B via a communication channel. For the first lifting device 110A, the PID controller 1110 receives the control signal from the lift controller 120 and the chain length and / or motor speed information from the length / speed sensor 1120, and controls the motor 1130 based on the control signal and the sensor signal to install the workpiece 130. Similarly, for the second lifting device 110B, the PID controller 1140 receives the control signal from the lift controller 120 and the chain length and / or motor speed information from the length / speed sensor 1150, and controls the motor 1160 based on the control signal and the sensor signal to install the workpiece 130. In some embodiments, the first lifting device 110A and / or the second lifting device 110B may communicate directly with the level sensor 1200 through a separate channel to receive the level signal and adjust operation accordingly (rather than receiving the level signal through the lift controller 120).

[0181] Figures 16 to 18 An example embodiment of a wireless lift system 100 is shown, in which a lift controller 120 sends a command to a first lift device 110 to install a workpiece 130, and the first lift device 110 transmits or generates further commands or provides operating information (e.g., motor speed, chain length) to at least a second lift device 110B, which forms the basis for the operation of the second lift device 110B. In the example shown, the lift controller 120 communicates wirelessly with the first lift device 110A. The first lift device 110A, in turn, communicates with the second lift device 110B to install the workpiece 130. For example, the lift controller 120 communicates with the first lift device 110A via a first wireless communication channel 810A, and the first lift device 110A communicates with the second lift device 110B via a second wireless communication channel 810B.

[0182] Figure 19 Shows the operation Figures 16 to 18FIG1 is a flow chart illustrating an example method 1900 for a wireless lift system 100. In the illustrated example, method 1900 includes receiving user input at user interface 340 of lift controller 120 (at block 1910). A user of wireless lift system 100 controls lift device 110 using lift controller 120. The user provides control input to lift controller 120 via user interface 340. For example, user interface 340 includes a joystick controller, and the user moves the joystick controller to produce movement of a workpiece via lift device 110. User interface 340 can receive user input from the user, including a plurality of operating parameters for a task to be performed by wireless lift system 100. The user input can include a desired movement of workpiece 130, such as a desired direction of movement of workpiece 130, a desired movement speed, a starting point, an end point, and the like. The user input can also include a position of first lift device 110A, a desired angle of level 1200, a desired end position of workpiece 130, and the like.

[0183] Method 1900 includes determining, using the controller electronic processor 310, a first operating parameter based on user input (at block 1920). The first operating parameter may correspond to the operation of the first lifting device 110A. The controller electronic processor 310 receives user input, such as a desired movement of the workpiece, a desired angle of the level 1200, and the position of the lifting device 110 and the workpiece, and determines the operating parameter of the first lifting device 110A based on the user input. For example, the controller electronic processor 310 receives the desired movement of the workpiece as user input and determines a movement direction and / or speed and / or chain length of the first chain 115A of the first lifting device 110A. The movement direction and / or speed and / or chain length of the first chain 115A corresponds to the first operating parameter. In another example, the controller electronic processor 310 receives the respective positions of the first and second lifts 110A, 110B and the desired end position of the workpiece as user input and determines the direction and / or speed and / or chain length of movement of the first chain 115A of the first lift 110A and / or the second chain 115B of the second lift 110B. In this example, the controller electronic processor 310 may also use the respective chain lengths of the first and second chains 115A, 115B from the first and second lifts 110A, 110B to determine the first operating parameter. For example, the controller electronic processor 310 may determine an initial position of the workpiece based on the position of the lifts 110 (e.g., received during a setup phase) and the respective chain lengths (determined by the respective sensors 260 of the lifts 110). The controller electronic processor 310 then finds the distance and direction between the initial position determined above and the desired end position received from the user input. The controller electronic processor 310 uses the distance and direction to calculate the direction of movement and / or speed of the first chain 115A and / or the chain length.

[0184] The method 1900 includes providing, using the controller electronic processor 310, a first control signal indicative of a first operating parameter wirelessly to the first lift device 110A (at block 1930). The controller electronic processor 310 provides the control signal corresponding to the first operating parameter to the first lift device 110A via the controller transceiver 330. The first lift device 110A receives the first control signal through the lift transceiver 230 (i.e., the first wireless transceiver). The first lift device 110A operates based on the first control signal. That is, the first lift device 110A controls the lift motor 250 (i.e., the first motor) of the first lift device 110A based on the first control signal. For example, the lift electronic processor 210 of the first lift device 110A controls the lift motor 250 of the first lift device 110A to match the direction, chain length, and / or speed indicated by the first control signal.

[0185] The method 1900 also includes providing, using the first lift device 110A, a second control signal wirelessly to the second lift device 110B (at block 1940). The lift electronic processor 210 provides the second control signal to the first lift device 110A and in turn to the second lift device 110B via the lift transceiver 230 based on the first control signal. The second lift device 110B receives the second control signal through the lift transceiver 230 (i.e., the second wireless transceiver). The first lift device 110A determines the second operating parameter corresponding to the operation of the second lift device 110B based on the first control signal received from the lift controller 120, for example, as described in the method 700. The second lift device 110B operates based on the second control signal. That is, the second lift device 110B controls the lift motor 250 (i.e., the second motor) of the second lift device 110B based on the second control signal. For example, the lift electronic processor 210 of the second lift device 110B controls the lift motor 250 of the second lift device 110B to match the direction, chain length, and / or speed indicated by the second control signal.

[0186] As Figure 18The control chart of FIG. 10A shows that some embodiments of the wireless hoist system 100 include determining desired parameter information using the controller electronic processor 310. For example, a user can input desired speed and position information into the hoist controller 120 using the user interface 340. The method also includes providing, using the controller electronic processor 310, a control signal indicative of the desired parameter information to the first hoist device 110A via the first communication channel 810A. The PID controller 1110 of the first hoist device 110A receives the control signal from the hoist controller 120 and chain length and / or motor speed information from the length / speed sensor 1120 (e.g., one or more hoist sensors 260 of the first hoist device 110A) and controls the motor 1130 (e.g., the motor 250 of the first hoist device 110A) to install the workpiece 130 based on the control signal and the sensor signal.

[0187] The first hoist device 110A also provides the speed of the first hoist device 110A to the second hoist device 110B using the hoist electronic processor 210A. The first hoist device 110A communicates with the second hoist device 110B over the second wireless communication channel 810B to provide the speed information to the second hoist device 110B. The PID controller 1140 of the second hoist device 110B receives the speed information from the first hoist device 110A and chain length and / or motor speed information from the length / speed sensor 1150 (e.g., one or more hoist sensors 260 of the second hoist device 110B) and controls the motor 1160 (e.g., the motor 250 of the second hoist device 110B) to install the workpiece 130 based on the speed signal and the sensor signal. In some embodiments, the hoist controller 120 can stop operation of the hoist devices if the speed or acceleration exceeds a predetermined maximum value. An example of the predetermined threshold can be 20% higher than the normal operating value. However, thresholds greater than 20% or less than 20% are also contemplated.

[0188] While some embodiments described herein are with respect to a single (first) lift device 110 or with respect to first and second lift devices 110, in some embodiments, two, three, or more lift devices 110 can be included. For example, the wireless lift system 100 can include a third lift device 110. Continuing with the method 700, the controller electronic processor 310 also determines a third operating parameter based on the user input (at block 720), and the method 700 further includes providing a third control signal to the third lift device 110 indicative of the third operating parameter. Turning to the method 1900, for the third lift device, an additional block (e.g., after block 1940) can be included in which the third control signal is provided to the third lift device using the first (or second) lift device 110. The third lift device 110 operates based on the third control signal. In these embodiments, the lift controller 120 communicates with the first lift device 110A over a first wireless channel 810, the first lift device 110A communicates with the second lift device 110B over a second wireless channel 810B (as previously described), and the first lift device 110A (or the second lift device 110B) communicates with the third lift device 110 over a third wireless communication channel 810C. As another example, the method 1500 can also operate with a third lift device 110, in which the third lift device 110 operates with the first and second lift devices 110 and the level 1400, similar to the manner in which the second lift device 110 is described as operating with the first lift device 110 and the level 1400.

[0189] Figure 20 A handheld remote control 2000 is shown, which can be used as the controller 120 in the various lift systems described herein. In the example shown, the handheld remote control 2000 includes a housing 2010, a variable speed trigger 2020, directional control buttons 2030, and a communication channel button matrix 2040. The handheld remote control 2000 takes the form of a joystick remote, such as those used in flight simulators and video game controllers. The handheld remote control 2000 can communicate with one or more lift devices 110 using one or more communication protocols (e.g., Bluetooth®, Wi-Fi®, ZigBee®, etc.).

[0190] ​The housing 2010 can be an elongated tubular housing that includes a grip portion 2012 and a top portion 2014. A variable speed trigger 2020 is disposed on the top portion 2014 just above the grip portion 2012. Direction control buttons 2030 are disposed on top of the top portion 2014. The grip portion 2012 and the top portion 2014 are arranged and sized so that a user holding the handheld remote control 2000 using the grip portion 2012 can use an index finger to pull or release the variable speed trigger 2020 and can use a thumb to push the direction control buttons 2030 disposed on the top portion 2014. Thus, the handheld remote control 2000 is designed for single-handed user operation.

[0191] The variable speed trigger 2020 is used to control the operating speed of the lift 110. Specifically, the speed of the lift varies between zero and a maximum speed, where the maximum speed corresponds to a maximum amount of pulling of the variable speed trigger 2020. Thus, the speed of the lift 110 is controlled by varying the amount of pulling of the variable speed trigger 2020. The variable speed trigger 2020 includes a body that has a spring biased member so that a user can pull the variable speed trigger 2020 from a home position by applying pressure to the variable speed trigger 2020, and the trigger 2020 returns to the home position when the user releases the variable speed trigger 2020. In some embodiments, a sensing pad and a wiper are disposed in the handheld remote control 2000 to determine the amount of pulling of the variable speed trigger 2020. The wiper is attached to the variable speed trigger 2020 so that the wiper moves with the variable speed trigger 2020 on the sensing pad. The resistance of the sensing pad varies depending on the position of the wiper on the sensing pad. The resistance of the sensing pad is detected by the controller electronics processor 310 to determine the amount of pulling of the trigger. In other embodiments, a Hall sensor design or an optical sensor design can be used to determine the amount of pulling of the variable speed trigger 2020.

[0192] In some embodiments, the variable speed trigger 2020 is configured to prevent a“lockout” condition, e.g., where the trigger gets stuck in a position, causing the user to be unable to cancel a previously commanded operation. In some examples, the variable speed trigger (or other inputs on the remote control 2000) can become contaminated with debris, tolerances, or misuse. In some embodiments, a rubber boot or other protective covering can be added to the variable speed trigger 2020 or other inputs on the remote control 2000, which can provide protection against contaminants as well as mechanical wear.

[0193] The remote control 2000 can also include one or more devices to reduce accidental operation of the remote control 2000. These devices can include an end switch, a trigger / actuator guard, and a double and / or triple activation trigger / switch / hand sensor. The double / triple activation trigger / switch / hand sensor is configured to require multiple operations by the user to generate a command. For example, the user can have to press a grip sensor on the remote control 2000 as well as press a variable speed trigger 2020 to achieve a desired output. Example grip sensors can include a capacitive sensor, a pressure sensor, or the like. In other embodiments, an accelerometer can detect motion and be used with an input operation (e.g., by the variable speed trigger 2020) to act as an additional input.

[0194] The remote control 2000 can also include a safety input, such as an end switch or emergency stop button to stop all movement of the lift 110. In one embodiment, the remote control 2000 (and / or the lift) can include a microphone or other audio input configured to recognize a vocal command or indicator related to stopping operation of the lift 110. For example, the audio input can be configured to recognize a loudened / raised voice / large noise and stop operation of the lift. In some examples, ambient sounds can also be determined via the audio input, such as transient noise, scraping noise, or other sounds indicative of undesired operation and / or potential interference with a load. In one embodiment, the controller of the remote control 2000 (described below) can be configured to process the audio input. In other embodiments, the lift controller 120 is configured to process the audio input. In one embodiment, an additional safety sensor, such as a pinch sensor, can be placed on the workpiece 130, which can output a signal to the remote control 2000 and / or the lift controller 120. For example, a person guiding the workpiece into place can activate the pinch sensor by applying a force to stop movement of the lift system 100. In other examples, the pinch sensor can be actuated if the workpiece 130 comes into contact with an object, thereby stopping operation of the lift 110.

[0195] The direction control button 2030 is used to control the direction of operation of the lift device 110. The direction control button 2030 includes an up direction button 2030A and a down direction button 2030B. The user can press one of the direction control buttons 2030 to select the direction of operation of the lift device 110. In one embodiment, the user can be required to keep one of the direction control buttons 2030 pressed during operation of the lift device 110. For example, the user can be required to actuate both the direction control button 2030 and the speed trigger 2020 to operate the lift device 110. In this embodiment, release of either the direction control button 2030 or the speed trigger 2020 can stop operation of the lift device 110. In other embodiments, the user can press the direction control button 2030 at the start of operation and operate the lift device 110 in the selected direction without the need for continuous actuation of the direction control button 2030.

[0196] In one embodiment, the lift controller 120 is configured to receive commands from the remote control 2000. The lift controller 120 can be configured with one or more safety interlocks to prevent undesired operation of the lift device. For example, the lift controller can be configured to monitor one or more electronic signals from the remote control 2000 and verify that the electronic signals (e.g., commands) are valid and within specifications. In some embodiments, in response to determining that an electronic signal is invalid, the lift controller 120 does not execute the requested command associated with the received signal. When the lift controller 120 is executing a command (e.g., moving the load up or down, etc.) and receives a subsequent electronic signal from the remote control 2000 that is determined to be invalid, the lift controller 120 stops the current operation and waits for the next valid electronic signal from the remote control 2000 that is determined to be valid. Similarly, in some examples, the remote control 2000 is configured to send redundant signals for all user input commands. The lift controller 120 can be configured to monitor the redundant command signals from the remote control 2000 and, in the event that the redundant signals are invalid, stop the current operation and / or prevent operation of the command. The lift controller 120 can determine that the redundant commands are invalid based on receiving only one of the two redundant signals and / or receiving different commands for each redundant command.

[0197] In other examples, the lift controller 120 is configured to provide one or more safety interlocks related to commands received from a remote source, such as the remote control 2000. For example, when the lift controller receives a command (e.g., up or down), the lift controller will only perform the operation during the command is issued. For example, if the lift controller 120 receives an up command, the lift controller 120 commands the lift to raise the load. If a problem is encountered, such as a mechanical problem, a power outage, a disruption in communication with the remote control 2000, etc., the lift controller 120 will stop operation. However, because the last valid command received was an up command, the lift controller will prevent the load from being lowered (e.g., a down operation). Similarly, if the last command received was a down command, the lift controller 120 will operate the lift 110 in a down mode, or stop operation if a problem occurs, but will not allow an up operation to be performed until a valid up command is received.

[0198] The communication channel button matrix 2040 can include a plurality of communication channel buttons, where each button corresponds to a communication channel of the handheld remote control 2000. Each communication channel can be programmed to communicate with a single lift 110. In the illustrated example, the communication channel button matrix includes four communication channel buttons to communicate with four separate lifts 110 (identified as 110A-D, respectively). A user can select one or more lifts 110 for the handheld remote control 2000 to control by pressing the corresponding communication channel button. In the illustrated example, the user has selected the first communication channel button 2040A and the second communication channel button 2040B to control the first lift 110A and the second lift 110B corresponding to the first communication channel button 2040A and the second communication channel button 2040B, respectively. Each communication channel button can also include a lighted indicator (e.g., an LED) to light up to indicate that the communication channel button is selected. In one implementation, the communication channel button lights up to indicate that the communication channel button is selected and does not light up when the communication channel button is not selected. In another implementation, the communication channel button lights up in a first color (e.g., green) to indicate that the communication channel button is selected and lights up in a second color (e.g., red) different from the first color to indicate that the communication channel button is not selected.

[0199] Figure 21A schematic view of the handheld remote control 2000 is shown. In the example shown, the handheld remote control 2000 includes a controller power source 345, a controller electronics 2042 (including a controller electronic processor 310 and a controller memory 320), a controller transceiver 330, a variable speed trigger 2020, directional control buttons 2030, and a communication channel button matrix 2040. The power source 345 is, for example, one or more AAA batteries that are inserted into a housing 2010 of the handheld remote control 2000. The power source 345 provides operating power to the electrical components of the handheld remote control 2000.

[0200] The controller transceiver 330 is, for example, a Bluetooth® chip, a radio frequency (RF) transceiver chip, or the like. The controller transceiver 330 includes an antenna 335 that is used to transmit and receive signals from the lift device 110. The controller transceiver 330 is coupled to the controller electronic processor 310 to receive control signals from the controller electronic processor 310 for transmission and for providing signals from the lift device 110 to the controller electronic processor 310.

[0201] The variable speed trigger 2020 is coupled to the controller electronic processor 310 to provide a speed control signal to the controller electronic processor 310. As described above, the variable speed trigger 2020 provides an indication of the amount of pull of the variable speed trigger 2020 to the controller electronic processor. The directional control buttons 2030 are coupled to the controller electronic processor 310 to provide actuation signals to the controller electronic processor 310.

[0202] For example, the first directional control button 2030A provides a signal when the first directional control button 2030A is pressed and does not provide any signal when the first directional control button is not pressed. The first directional control button 2030A can continue to provide a signal as long as the first directional control button 2030A remains pressed. In one example, when the first directional control button 2030A is pressed, the first directional control button 2030A closes a circuit that forms a current path from the controller electronic processor 310 to ground and draws current from the controller electronic processor 310. When the controller electronic processor 310 detects that current is being drawn from a port connected to the first directional control button 2030A, the controller electronic processor 310 determines that the first directional control button 2030A is pressed. When the first directional control button 2030A is released, the circuit is opened, thereby terminating the current draw from the controller electronic processor 310.

[0203] ​Similarly, the second direction control button 2030B provides a signal when the second direction control button 2030B is pressed and does not provide any signal when the second direction control button is not pressed. The second direction control button 2030B can continue to provide a signal as long as the second direction control button 2030B remains pressed. In one example, when the second direction control button 2030B is pressed, the first direction control button 2030B closes a circuit that provides a current path from the controller electronic processor 310 to ground and draws current from the controller electronic processor 310. When the controller electronic processor 310 detects that current is being drawn from the port connected to the first direction control button 2030B, the controller electronic processor 310 determines that the first direction control button 2030A is pressed. When the second direction control button 2030B is released, the circuit is opened, thereby terminating the current draw from the controller electronic processor 310. In the illustrated example, the first direction control button 2030A corresponds to up and the second direction control button 2030B corresponds to down.

[0204] The communication channel button matrix 2040 is coupled to the controller electronic processor 310 to provide control signals to the controller electronic processor 310. The communication channel button matrix 2040 includes four communication channel buttons 2040A, 2040B, 2040C, 2040D. The operation of the communication channel buttons is similar to the direction control buttons 2030A described above. However, in at least some implementations, the communication channel buttons are toggle switches, such that the communication channel buttons can be pressed once to turn the communication channel on and pressed again to turn the communication channel off. That is, the communication channel buttons do not need to be continuously pressed.

[0205] The communication channel button matrix 2040 also includes a plurality of indicators 2045A, 2045B, 2045C, 2045D corresponding to the four communication channel buttons. The plurality of indicators receive control signals from the controller electronic processor 310. In some implementations, the indicators light up or their color is changed (e.g., from red to green) when the corresponding one of the communication channel buttons is activated.

[0206] Figure 22 A schematic diagram of the lift device 110 is shown. In the illustrated example, the lift device 110 includes a lift power source 240, a lift electronic controller 2047 (including a lift electronic processor 210 and a lift memory 220), and a lift transceiver 230. The power source 345, for example, is a power tool battery pack that includes a terminal block and is coupled to a terminal block on the housing of the lift device 110. The power source 345 provides operating power to the electrical components of the lift device 110, including the motor 250 Figure 22 (not shown in FIG. 2) and the lift electronic controller 2047. Although in the illustrated example the power source 345 is a power tool battery pack, in other examples, the power source 345 can be a wired power source, such as a wall outlet. Figure 22The lift electronic controller 2047 is shown as including two control boards, but in some embodiments, the lift electronic controller 2047 is a single control board that includes the lift electronic processor 210 and the lift memory 220. For ease of description, the processors of the control boards of the lift electronic controller 2047 will be referred to collectively as the lift electronic processor 210.

[0207] The lift transceiver 230 is, for example, a chip, a radio frequency (RF) transceiver chip, or the like. The lift transceiver 230 includes an antenna 235 for transmitting and receiving signals from the handheld remote control 2000. The lift transceiver 230 is coupled to the lift electronic processor 210 to receive signals from the lift electronic processor 210 for transmission and to provide control signals from the handheld remote control 2000 to the lift electronic processor 210.

[0208] Referring back to Figure 20 , each communication channel button can be programmed to communicate with a single lift device 110. Specifically, the address or radio frequency address of each lift device 110 can be hard-coded into the controller electronic processor 310 (e.g., permanently or semi-permanently stored in the lift memory 220) and associated with a respective one of the communication channel buttons. Each coded lift device 110 can only be activated when the respective communication channel button is pressed and the respective LED is illuminated. Selecting more than one lift device 110 allows each selected lift device 110 to be controlled simultaneously using the handheld remote control 2000. Furthermore, as discussed further above, the activated lift devices 110 can communicate with each other to coordinate movement of the workpiece 130. In some embodiments, to increase safety, the lift devices 110 can be configured to stop operating when no signals are received from the handheld remote control 2000. In some embodiments, each communication channel button can be paired with a lift device 110 on the fly, rather than being hard-coded. The pairing operation can be performed similarly to the pairing or other RF communication protocol pairing. This allows extra flexibility in the system by allowing a user to use the same handheld remote control 2000 with multiple lift devices 110. Furthermore, a lost or damaged handheld remote control 2000 can be easily replaced by pairing a new handheld remote control 2000 with the lift devices 110.

[0209] In some embodiments, each lift device 110 can only be paired with one handheld remote control 2000 at a time. For example, each lift device can only store the active address of one handheld remote control 2000 at a time. As such, the lift devices 110 can avoid receiving multiple control signals from different handheld remote controls 2000 at the same time or control signals that conflict with each other.

[0210] In some embodiments, each lift device 110 can only be paired with one handheld remote control 2000 at a time. For example, each lift device can only store the active address of one handheld remote control 2000 at a time. As such, the lift devices 110 can avoid receiving multiple control signals from different handheld remote controls 2000 at the same time or control signals that conflict with each other.​​

[0211] In some embodiments, each indicator 2045 associated with a communication channel button can emit light in a different color (e.g., one of red, blue, yellow, and green). The lift device 110 can include similar indicators 2050 on the device. Referring to FIG. 21, the user can see the indicators 2045 and 2050 and easily identify the correspondence between each communication channel button and the lift device 110. Figure 23 When the lift device 110 successfully pairs with a communication channel button, the indicator 2045 corresponding to the communication channel button and the indicator 2050 on the lift device 110 can emit light in the same color. This allows the user to easily identify the correspondence between each communication channel button and the lift device 110.

[0212] In some embodiments, the controller transceiver 330 can be configured to transmit on a unique frequency that is not associated with other devices within a certain range of the lift device 110. In one embodiment, the controller transceiver 330 is configured to listen for other signals at or near the operating frequency of the remote control 2000 and / or the lift device 110 and perform an action if a potential interfering signal is detected. In one embodiment, the controller transceiver 330 can stop operating and generate an alert to the user indicating that another device is using the operating frequency. The user can then change the operating frequency of the controller transceiver 330 or the user can disable the device causing the interference (or modify its operating frequency). In other embodiments, the controller transceiver can automatically switch to a different frequency that is different from the interfering frequency. For example, the controller transceiver 330 can use frequency hopping as long as interference is detected. In addition, the controller transceiver 330 can also control other wireless transceivers associated with the lift device 110 to switch frequencies accordingly.

[0213] In one embodiment, the controller transceiver 330 is configured to pair with one or more lift devices 110 using an encrypted communication protocol to prevent other devices from interfering with the communication between the remote control 2000 and the lift device 110. In addition, as described above, the lift controller 120 can perform a redundancy check on the commands received from the remote control 2000 to ensure the commands are valid. In other examples, the controller transceiver 330 is configured to send multiple signals (redundant or different), and the lift controller 120 checks the accuracy and validation of these signals before executing the command.

[0214] In other examples, the controller transceiver 330 and / or the lift controller 120 performs a time-based signal quality and / or accuracy check on all received signals. The time-based signal check evaluates the signal over a period of time to verify that the signal is acceptable and verifiable. This helps to distinguish between noise and an actual signal. In other implementations, the receiving device (i.e., the controller transceiver 330 and / or the lift controller 120) can evaluate the strength of the received signal and only execute a command related to the received signal if the signal strength is above a signal strength threshold. In one implementation, the controller transceiver 330 and / or the lift controller 120 can use a received signal strength based location determination algorithm (RSSI) and will only execute a command if the relevant received signal is within a threshold distance. In further implementations, the controller transceiver 330 can be configured to only connect with the lift controller 120 through line of sight communication (e.g., infrared (IR) or other line of sight communication protocol).

[0215] Referring to Figure 21 and Figure 22 , the lift devices 110 provide indications of speed, direction, and load to the lift devices 110 and the handheld remote 2000 that are operating simultaneously with each other. Referring to Figures 4A to 4C As described further below, the speed and load information can be used to move the workpiece 130 in unison. Referring to Figure 5 The speed and load information can also be used to cause each of the lift devices 110 to move at different speeds and directions to move the workpiece 130 from a first position to a second position.

[0216] In some implementations, a smart phone can be used instead of or in addition to the handheld remote 2000. Figure 24A user interface 2400 on a smartphone is shown that allows for operation of a connected lift device. In the example shown, the user interface 2400 is disposed on a touchscreen such that different portions or pages of the touchscreen form different user inputs (e.g., the variable speed trigger 2020, the direction control buttons 2030, and the communication channel button matrix 2040). In some embodiments, the smartphone is configured to communicate with the lift device 110 to configure the lift device 110, retrieve operational data (e.g., logged data indicative of usage, malfunctions, etc.), and transmit operational data and location information related to the lift device 110 to a remote server. The location information can be determined from a GPS receiver on the smartphone and added to the operational information and identity of the lift device when sent to the remote server. Since the smartphone communicates with the lift device 110 through a local, short-range wireless communication protocol, the location information of the smartphone is an acceptable proxy for the location of the lift device 110. The remote server in turn can provide the received information to another client device (e.g., another smartphone or personal computer), such that location and operational data related to a group of lift devices 110 can be tracked and monitored.

[0217] Figures 25A to 25C Another embodiment of a handheld remote control 2000 is shown. In the example shown, the handheld remote control 2000 includes a variable speed trigger 2020, a communication channel button matrix 2040, a system health indicator 2500, a remote control battery indicator 2510, and a speed dial 2520. The variable speed trigger 2020 is disposed on a side of a housing 2010 of the handheld remote control 2000. The communication channel button matrix 2040 includes, for example, four translucent communication channel buttons with LEDs or other light-emitting devices underneath the communication channel buttons.

[0218] Reference is made to Figure 25B The LEDs of the communication channel buttons can light up in different colors and flashing patterns to indicate different states of the respective lift devices 110 to which they are associated. For example, the LEDs can be off to indicate that the lift device 110A is in an inactive state due to a power outage, the lift device 110 is not selected for operation, etc. The LEDs can flash in a first color (e.g., orange) to indicate an error state of the respective lift device 110. The LEDs can light up in the first color without flashing to indicate that the lift device has not been secured, which can be indicated, for example, when the smart hook 3600 indicates to the remote control 2000 that the hook latch 3606 is open (see FIG. 36). The LEDs can light up in a second color (e.g., green) to indicate that the respective lift device 110 is in an active state and is ready for operation. The LEDs can flash in the second color to indicate that the respective lift device 110 is in the process of being secured, which can be indicated, for example, when the smart hook 3600 indicates to the remote control 2000 that the hook latch 3606 is in the process of being closed (see FIG. 36). Figure 36). The LED can flash in a second color (e.g., red) to indicate that the corresponding lift device 110 is overloaded. The LED can glow in the second color without flashing to indicate that the lift power source 240 of the corresponding lift device 110 is depleted below an operational level (or the battery is dead). The LED can flash in a third color (e.g., green) to indicate that the corresponding lift device 110 battery is low. The LED can glow in the third color without flashing to indicate that the corresponding lift device 110 is active and functioning normally. The LED can also be used for other warnings and alerts, such as overload warnings, etc.

[0219] Referring to Figure 25A , the system health indicator 2500 can provide an indication of the overall system health of the lift system 100. The system health indicator 2500 includes three LEDs that glow in a single color or multiple colors. The system health indicator 2500 can have all three LEDs glowing to indicate that all components are functioning correctly. One or more LEDs can not glow to indicate that one or more components of the system 100 can not be functioning correctly. The remote control battery indicator 2510 provides an indication of the battery level of the controller power source 345. In the example shown, the remote control battery indicator 2510 includes four LEDs that can be glowing to correspond to the current battery level of the controller power source 345 (e.g., four glows indicates a full charge, three glows indicates ¾ charge, two glows indicates ½ charge, one glow indicates ¼ charge, and no glow indicates no charge).

[0220] Referring to Figure 25CThe variable speed trigger 2020 can be implemented using a dual trigger design with a first trigger 2020A and a second trigger 2020B. The first trigger 2020A is disposed below the top portion 2014 for operation by the user’s index finger, and the second trigger 2020B is disposed above the top portion 2014 for operation by the user’s thumb. In some embodiments, the amount of trigger pull of both triggers 2020A-B corresponds to a PWM duty cycle (in the range of 0-100%) of a signal used to drive the lift motor 250 controlled by the handheld remote 2000. The PWM duty cycle to drive the lift motor 250 is directly proportional to the speed of the lift motor. In some embodiments, the amount of pull of the first trigger 2020A is mapped to the entire range of PWM duty cycle, such that for every 10% of the total potential trigger travel, the PWM duty cycle is increased by 10% until the first trigger 2020A is fully depressed (100%), at which point the PWM duty cycle is set to 100%. In some embodiments, the amount of pull of the second trigger 2020B is mapped to a decreasing range of PWM duty cycle, such that for every 10% of the total potential trigger travel, the PWM duty cycle is increased by 1% until the first trigger 2020A is fully depressed (100%), at which point the PWM duty cycle will be 10%. In some embodiments, the sum of the duty cycles indicated by both triggers 2020 is summed up to a cap of 100% to determine the PWM duty cycle used to drive the lift motor 250. Thus, for example:

[0221] When the first trigger 2020A is fully released (representing 0% duty cycle) and the second trigger 2020B is fully depressed (representing +10% duty cycle), the total PWM duty cycle is set to 10%;

[0222] When the first trigger 2020A is pulled halfway (representing 50% duty cycle) and the second trigger 2020B is pulled halfway (representing +5% duty cycle), the total PWM duty cycle is set to 55%; and

[0223] When the first trigger 2020A is fully depressed (representing 100% duty cycle), the total PWM duty cycle is set to 100% no matter how small the amount of pull of the second trigger 2020B.

[0224] Accordingly, in at least some implementations, the first trigger 2020A provides a larger change in velocity for each successive pull and has a larger control range (e.g., 0-100% duty cycle), while the second trigger 2020B provides a smaller change in velocity for each successive pull and has a smaller control range (e.g., 0-10% duty cycle). In some implementations, the first trigger 2020A can be used for larger movements (e.g., larger distances) of the workpiece 130 while the second trigger 2020B is used for finer movements (e.g., smaller distances) of the workpiece 130. In another implementation, the first trigger 2020A and the second trigger 2020B are not used simultaneously, but rather, for example, the other trigger signal is ignored when one trigger signal has been activated.

[0225] In some implementations, instead of varying the speed of the motor based on the amount of trigger press of the remote control 120 or 2000, a speed dial 2520 or another speed selector input button or slider can be used to set a particular speed (e.g., low, medium, and high) of the lift motor 250. In some implementations, a smart phone can be used to program the speed dial 2520 to particular speeds. These set speeds can be used as the desired speed in a closed loop control function implemented by the lift electronics processor 210 such that the set speed is generally held constant. In other words, the lift electronics processor 210 measures the speed of the motor 250, compares it to the desired speed, and adjusts the current to the motor (e.g., by adjusting the PWM duty cycle driving the motor) to maintain the speed of the motor 250 at the desired speed. In other implementations, the lift electronics processor 210 implements an open loop control function such that the desired speed maps to a particular current (e.g., particular PWM duty cycle) to the motor 250, which is then used to drive the motor 250.

[0226] In some implementations, the lift device 110 can be provided with a work light to illuminate the work surface, the workpiece 130, or the area in which the workpiece 130 moves. For example, the work light can direct light toward the workpiece and the surrounding area. The lift device 110 can also include an indicator that provides a visible notification and / or a speaker that provides an audible notification (e.g., emits a beep, an alarm, a voice notification, etc. to the user). The indicator and the speaker can be used in conjunction with other techniques and methods described herein to provide different notifications, alerts, or indications.

[0227] In some embodiments, the lift system 100 can impose a distance limit on the lift device 110 and the controller 120. Specifically, to ensure that the lift device 110 can accurately receive signals, the lift system 100 can prevent operation of the lift device 110 when the distance between the controller 120 and the lift device 110 is greater than a predetermined amount. The controller 120 can use the propagation delay of a round-trip signal from the controller 120 to the lift device to determine the distance between the controller 120 and the lift device 110.

[0228] Figure 26A and Figure 26B A method for calculating the distance between the controller and the lift device 110 is shown. Figure 26B is a flowchart of an example method 2600 for determining the distance between the controller 120 and the lift device 110. In the example shown, the method 2600 includes synchronizing the clocks of the controller 120 and the lift device 110 (at block 2610). The clocks can be synchronized when the controller is paired with the lift device 110. In some embodiments, both the controller 120 and the lift device 110 can include a global positioning system (GPS) to receive universal time. The clocks of the controller 120 and the lift device 110 are then synchronized with the universal time. In some embodiments, the clocks are synchronized according to the method provided in and further described below in Figure 27A and Figure 27B synchronizing the clocks according to the method provided in and further described below in

[0229] The method 2600 also includes sending, using the controller 120, a timing signal including a first time to the lift device 110 (at block 2620). The controller 120 can record the first time and embed the first time into the timing signal, for example by timestamping the timing signal. The first time corresponds to the time at which the timing signal is sent from the controller 120.

[0230] The method 2600 includes receiving, at the lift device 110, the timing signal from the controller 120 at a second time (at block 2630). The lift device 110 can record the time at which the lift device 110 receives the timing signal. The method 2600 also includes determining, using the lift electronic processor 210, a distance between the controller 120 and the lift device 110 based on the first time and the second time (at block 2640). In one example, the lift electronic processor 210 determines the distance by calculating the propagation time and multiplying the propagation time by a known transmission speed (i.e., the speed of light). The lift electronic processor 210 calculates the propagation time by subtracting the first time from the second time. In some embodiments, the lift electronic processor 210 can adjust the propagation time to account for processing delays of the controller 120 and / or the lift device 110.

[0231] Method 2600 includes determining, using hoist electronic processor 210, whether the distance between controller 120 and hoist 110 is below a predetermined threshold (at block 2650). Hoist electronic processor 210 compares the distance between controller 120 and hoist 110 to a predetermined amount. When the distance between controller 120 and hoist 110 is below the predetermined threshold, method 2600 includes allowing controller 120 to control the operation of hoist 110 (at block 2660). When the distance between controller 120 and hoist 110 is above the predetermined threshold, method 2600 includes performing a predetermined action (at block 2670). The predetermined action can include providing an indication on hoist 110 and / or providing an indication on controller 120. The indication notifies the user that controller 120 is not within the operating distance of hoist. The predetermined action can also include preventing controller 120 from operating hoist 110. For example, hoist 110 can ignore commands from controller 120 until method 2600 is performed again and the distance is determined to be below the predetermined threshold.

[0232] Figure 27A and Figure 27B Method 2700 is provided for synchronizing the clocks of controller 120 and hoist 110. Method 2700 includes transmitting, using controller 120, a transmission signal to hoist 110 at a first time (at block 2710). Controller electronic processor 310 records the first time. Method 2700 also includes receiving, at controller 120, a reply signal from hoist 110 at a second time (at block 2720). Hoist 110 provides the reply signal in response to receiving the transmission signal. Method 2700 also includes determining, using controller electronic processor 310, a timing offset based on the first time and the second time (at block 2730). Controller electronic processor 310 calculates the timing offset by dividing the propagation delay by two. The propagation delay represents the time required for a round-trip signal from controller 120 to hoist 110 and back to controller 120. Thus, the timing offset represents the time required for a signal to reach hoist 110 from controller 120. The propagation delay is calculated by subtracting the second time from the first time. The propagation delay can be adjusted by subtracting the processing delay introduced by hoist 110. Controller 120 can be preprogrammed to include the processing delay of hoist 110. Method 2600 also includes sending, using controller 120, a synchronization signal to hoist 110 that includes a third time and the timing offset (at block 2740). The third time represents the time at which controller 120 sends the synchronization signal. Hoist 110 synchronizes the clock of hoist 110 to the third time plus the timing offset, such that the clock of hoist 110 is synchronized to the clock of controller 120.

[0233] In some embodiments, controller 120 and hoist 110 use Communication Protocol to Exchange Control and Other Signals In other embodiments, the handheld remote control 2000 and the lifting device 110 may use a proprietary radio frequency (RF) communication protocol to exchange control and other signals.

[0234] 28A to 28D The signal exchange between the controller 120 and the lifting device 110 using a proprietary RF communication protocol is shown. The proprietary RF communication protocol uses dual identifiers, one broadcast from the controller 120 and a separate identifier for each lifting device 110. Figure 28D The pairing process between controller 120 and lifting device 110 is shown. Pairing can be initiated on either device or both devices simultaneously. During the pairing process, controller 120 broadcasts a pairing signal to lifting device 110 that includes an identifier for controller 120. Lifting device 110 stores the identifier for controller 120 and responds with an identifier for lifting device 110 and / or an identifier for controller 120. Controller 120 stores the identifier for lifting device 110. The pairing process is now complete, and controller 120 and lifting device 110 further communicate using a new identifier generated to include the identifiers for controller 120 and lifting device 110. In other embodiments, the RF communication protocol may use other communication methods, for example, a separate communication channel may be used for each lifting device 110.

[0235] Figure 28A FIG. 1 shows a communication method between the controller 120 and the lifting device 110. In one embodiment, the controller 120 sends a first broadcast signal to the first lifting device 110A. Figure 28C As shown, the first broadcast signal includes a first identifier corresponding to the controller 120 and the first lifting device 110A (e.g., a combination of the identifier of the controller 120 and the identifier of the first lifting device 110A), a command (e.g., specifying speed, direction, etc.), a timestamp (e.g., for distance calculation), padding, and a checksum (for signal accuracy verification). In response to receiving the first broadcast signal, the first lifting device 110A sends a first service data packet to the controller 120. Figure 28CThe first service data packet includes a first identifier, a distance of the first lift 110A from the controller 120, an ongoing operation (e.g., direction and speed), a status (e.g., sensor readings (e.g., load, speed, etc.)), and a checksum (for signal accuracy verification). In this embodiment, the controller 120 transmits a second broadcast signal to the second lift 110B after receiving the first service data packet and transmits a third broadcast signal to the third lift 110C after receiving the second service data packet from the second lift 110B. In other embodiments, the controller 120 can transmit the first broadcast signal, the second broadcast signal, and the third broadcast signal simultaneously or in rapid succession. The controller 120 receives the first service data packet, the second service data packet, and the third service data packet from the first lift 110A, the second lift 110B, and the third lift 110C, respectively. The first service data packet, the second service data packet, and the third service data packet are received in response to the first broadcast signal, the second broadcast signal, and the third broadcast signal, respectively. In some embodiments, the RF communication protocol can use different strategies for stop commands from the controller 120 to the lifts 110. Specifically, unlike operation signals, the controller 120 can repeatedly provide stop signals to the lifts 110 until a service data packet is received from the lifts 110 acknowledging the stop command. Although described using a proprietary RF communication protocol, the above-described method can be used with other communication protocols, such as 4G, 5G, infrared, etc. Additionally, the above-described RF communication method can use channel identifiers and can establish communication between the controller 120 and each lift 110 over separate channels, rather than using dual identifiers.

[0236] In some embodiments, rather than communicating with each lift 110 individually, the controller 120 can communicate with a single lift 110, which in turn communicates with other lifts 110. For example, as shown in FIG. 6, the first lift 110A, the second lift 110B, and the third lift 110C are daisy-chained together. In this example, the controller 120 provides control signals for each lift to the first lift 110A. The first lift 110A extracts the control signal for the first lift 110A and transmits the control signals for the second lift 110B and the third lift 110C to the second lift 110B. Similarly, the second lift 110B extracts the control signal for the second lift 110B and transmits the control signal for the third lift 110C to the third lift 110C. The first lift 110A, the second lift 110B, and the third lift 110C then operate using the control signals received from the controller 120. The above-described method can be used with other communication protocols, such as Figure 28B Figures 16 and 17 ​The implementation scheme uses a similar communication scheme.

[0237] In some embodiments, two or more lifting devices 110 can be tied together for simultaneous operation. Binding can be performed on the user interface of the lifting device 110 and / or the user interface of the handheld remote control 2000. In some embodiments, binding can also be performed on a connected smartphone device running an application designed to operate with the lifting device system described herein. When two or more lifting devices 110 are tied together, the lifting devices 110 can exchange operating and control signals to work together to perform a task.

[0238] Figures 29A to 29C An example of multiple lifter load balancing performed when two or more lifts 110 are used to lift a single workpiece 130 is shown. Figures 29A to 29C In the example shown, first and second lifts 110A, 110B are used to lift workpiece 130, and method 2900 is described with respect to two lifts 110. However, method 2900 is equally applicable to any number of lifts working together and / or in unison to lift a single workpiece 130. Figure 29C is a flow diagram of an example method 2900 for load balancing of multiple elevators.

[0239] exist Figure 29C In the example shown, the method 2900 includes recording a starting configuration (at block 2910). The starting configuration varies based on the desired lifting configuration of the workpiece 130. Figure 29A , when the workpiece 130 has equal weight distribution and is to be lifted to a horizontal height (ie, 0 degrees from the ground), the starting configuration includes the load and speed on the first lifting device 110A being equal to the load and speed on the second lifting device 110B. Figure 29B When the load is unevenly distributed or when the workpiece 130 is lifted at an angle different from the horizontal, the load and speed on each lifting device 110 may be different. In this example, at the beginning of the lifting operation, the first lifting device 110A records the load on the first lifting device 110A (e.g., based on a load sensor) and the second lifting device 110B records the load on the second lifting device 110B. In some embodiments, the first lifting device 110A and the second lifting device 110B provide load signals to the controller 120, which can monitor the load on each lifting device 110.

[0240] The method 2900 includes determining a corresponding first speed level for the first lifting device 110A based on the load on the first lifting device 110A and the load on the second lifting device 110B (at block 2920). The method 2900 also includes determining a corresponding second speed level for the second lifting device 110B based on the load on the first lifting device 110A and the load on the second lifting device 110B (at block 2930). The first speed level and the second speed level are selected to maintain the starting load configuration on each lifting device 110 throughout the lifting process. Thus, the ratio between the first speed level and the second speed level is inversely proportional to the ratio between the load on the first lifting device 110A and the load on the second lifting device 110B.

[0241] The method 2900 includes operating the first lifting device 110A at the first speed level (at block 2940) and operating the second lifting device 110B at the second speed level (at block 2950). As long as the load on the first lifting device 110A and the load on the second lifting device 110B are consistent with the starting configuration (e.g., within a predetermined percentage or other threshold of the starting configuration), the method 2900 maintains the first speed level and the second speed level.

[0242] The method 2900 includes determining whether the load on the first lifting device 110A is different from the starting configuration (at block 2960) and determining whether the load on the second lifting device 110B is different from the starting configuration (at block 2970). When the load on the first lifting device 110A and the load on the second lifting device 110B are consistent with the starting configuration (e.g., within a predetermined percentage or other threshold of the starting configuration), the method 2900 returns to blocks 2940 and 2950 to maintain the current operation.

[0243] When the load on the first lift 110A and / or the load on the second lift 110B is inconsistent with the starting configuration (e.g., the load is outside of a predetermined percentage or other threshold of the starting configuration), the method 2900 includes operating the first lift 110A and the second lift 110B to return to the starting configuration (at block 2980). For example, the method 2900 can stop operation and then can operate one or both of the first lift 110A and the second lift 110B to return to the starting configuration. Once returned to the starting configuration, the method 2900 returns to blocks 2920 and 2930 to continue operation. In some embodiments, the method 2900 can include determining a new speed level based on the new load configuration and operating the lifts 110 based on the new speed level instead of returning to the starting configuration. For example, if the first lift 110A detects an increased load (which should correspond to the second lift 110B detecting a decreased load), in block 2980, the first lift 110A can be controlled to increase its speed and / or the second lift 110B can be controlled to decrease its speed, thereby shifting more of the load to the second lift 110B and returning to the starting configuration. Similarly, if the first lift 110A detects a decreased load (which should correspond to the second lift 110B detecting an increased load), in block 2980, the first lift 110A can be controlled to decrease its speed and / or the second lift 110B can be controlled to increase its speed, thereby shifting more of the load to the first lift 110A and returning to the starting configuration.

[0244] In some embodiments, the two paths between block 2910 recording the starting configuration and block 2980 returning to the starting configuration (i.e., the path including block 2920, block 2940, and block 2960 and the path including block 2930, block 2950, and block 2970) can be executed in parallel, such that each of the first lift 110A and the second lift 110B can continuously adjust the motor speed to maintain the starting configuration.

[0245] Figure 30 A tilt winch 3000 is shown that can be used with the lift 110 to lift the workpiece 130. The tilt winch 3000 is powered by a winch power source 3010. The winch power source 3010 can be similar to the lift power source 240, e.g., a power tool battery pack. The tilt winch 3000 can be controlled by a winch controller 3020, which can be a separate controller or can be integrated into the controller 120. The tilt winch 3000 can be attached to the hook of the lift 110 and can communicate with the lift 110 and the controller 120 to operate with the lift 110.

[0246] The tilt winch 3000 includes two rope openings 3030 provided on each side of the housing 3040 of the tilt winch 3000. The rope openings 3030 provide an exit for the rope 3050 that can be pulled in and out by the tilt winch 3000. The tilt winch 3000 can include a motor similar to the motor of the lift 110 to adjust the length of the rope 3050. The rope 3050 can be tied on each side of the workpiece 130. The tilt winch 3000 is then operated (e.g., the winch motor is controlled) to adjust the length and / or tension of the rope 3050 on each side of the tilt winch 3000. In some embodiments, a third opening can be provided at the bottom of the winch housing 3040 to allow a second rope 3060 to be pulled in or out. The second rope 3060 can be provided in addition to or as an alternative to the rope 3050. The length and tension of the second rope 3060 can be adjusted using a winch controller 3020 similar to the rope 3050.

[0247] Now turning to Figure 31 , a flowchart illustrates a process 3100 for determining a last lift of a direct current battery powered lift (e.g., the lift 110). In some embodiments, the process 3100 is performed by an electronic processor of one of the lift systems described herein, such as the lift electronic processor 210 or the controller electronic processor 310. At process block 3102, the electronic processor determines a voltage drop of the power source (e.g., the lift power source 240). The voltage drop can be the voltage drop from the start of the lift to the end of the lift (e.g., when the motor stops). At process block 3104, the electronic processor determines an actual voltage level of the battery. At process block 3106, the electronic processor determines an average current of the motor during the lift. At process block 3108, the electronic processor determines a remaining power of the power source. In one embodiment, the remaining power of the power source is determined by multiplying the difference between the actual voltage of the battery and the minimum voltage of the power source by the power of a standard lift. In one example, the minimum voltage can be stored in a memory of the electronic processor. In some cases, the minimum voltage can be communicated to the electronic processor by the power source. The power of a standard lift can be calculated as the average current during the lift divided by the determined voltage drop.

[0248] At process block 3110, the number of lifts remaining in the power supply is determined by dividing the amount of power remaining in the power supply determined at process block 3108 by the amount of power for a standard lift. If the number of lifts remaining is determined to be less than 2 at process block 3112, the user is alerted that there is only one lift remaining in the power supply. In some embodiments, the alert can be a visual alert provided on the remote control 2000, as described above. For example, the alert can be presented by one or more LEDs or by a user interface (e.g., an LCD screen). In other embodiments, an audio or haptic alert can be provided to the user, alone or in combination with the visual alert described above. If the number of lifts is not less than 2, the number of lifts remaining is displayed for the user at process block 3114. For example, the number of lifts remaining can be displayed through a user interface of the remote control 2000.

[0249] For example, if the minimum voltage of the power supply is 14V, the voltage drop is 0.5VDC, the actual voltage of the power supply is 16V, and the average current is 10A, the amount of power remaining can be calculated as: 16V - 14V * (10A / 0.5) = 40W. Then, with a standard lift of 20W, the number of lifts remaining can be calculated as: 40W / 20W = 2.

[0250] Turning now to Figure 32 the process 3200 for controlling a soft start function of a motor (e.g., a motor of the lift device 110). The soft start function can be controlled by an electronic processor (e.g., the lift electronic processor 210 or the controller electronic processor 310) of one of the lift systems described herein. In one embodiment, the soft start function is configured to increase the acceleration of the motor at a speed lower than full speed to reduce inrush current, as well as to reduce excess stress on the motor. At process block 3202, the lift device begins a lift and the electronic processor begins to accelerate the motor at a standard soft start level. In some embodiments, this is a predetermined acceleration. In other embodiments, the user is able to select a soft start acceleration within a range of accelerations (e.g., using a user interface on a smartphone or remote control 120, 2000 connected wirelessly). The electronic processor can be configured to control the acceleration and speed of the motor by varying a pulse width modulation (“PWM”) signal to the motor. By increasing or decreasing the duty cycle of the PWM output to the motor, the controller can increase or decrease the acceleration and speed of the motor, respectively.

[0251] The electronic processor then monitors the magnitude of the change in the load being lifted at process block 3204. In some embodiments, the magnitude of the load can be determined based on the output of a load sensor. The load sensor can monitor the pressure in the hydraulic fluid, or the strain on the load carrying chain or other connection between the load and the lifting device 110. In other examples, the current of the motor 250 can be used to determine the magnitude of the load being lifted by the lifting device 110. At process block 3206, the electronic processor determines whether the magnitude of the load has been increased by more than a soft start limit. In some embodiments, the soft start limit is a ratio of the motor acceleration to the load. In response to the load magnitude increasing by more than the soft start limit, the electronic processor reduces the acceleration of the motor 250 at process block 3208 (e.g., by reducing the PWM duty cycle that controls the drive to the motor 250). In one embodiment, the electronic processor reduces the acceleration so that the acceleration is inversely proportional to the magnitude of the load change, such as Figure 33 After reducing the motor acceleration, the electronic processor returns to monitoring the magnitude of the load change at process block 3204.

[0252] In response to determining that the load magnitude has not increased beyond the soft-start limit, the electronic processor increases motor acceleration (e.g., by increasing the PWM duty cycle controlling the drive of motor 250) at process block 3210. In some embodiments, the acceleration does not increase beyond a predetermined level (e.g., an acceleration limit specified by a predetermined soft-start ramp). The controller then resumes monitoring the magnitude of the load change at process block 3204.

[0253] Now turn Figure 34 , shows an example system for determining the size of a load on a chain lifter, such as lift system 100, according to some embodiments. Generally, load sensing within a chain lifter can be accomplished using one or more static and dynamic measurements. Figure 34 An illustration of a static load determination system 3400 is provided. To obtain a static load value, measurements must be taken while the load is being lifted and freely suspended on a lifter 3402. As described above, the lifter 3402 can be connected to a support (e.g., a ceiling, a structural beam, etc.) via a first connector 3404. It should be understood that the lifter 3402 can be similar to the lift 110 or other lifts described herein. The first connector 3404 can be a chain, cable, strap, rope, etc. The load is then suspended from the lifter 3402 via a second connector 3406 (e.g., a chain or cable). Figure 34As shown, the load sensing device 3408 can be coupled to the first connector 3404 between the connection point and the lift 3402. In one embodiment, the sensing device 3408 is a hydraulic cylinder placed between the first connector 3404 and the lift 3402. As the load increases, the pressure within the hydraulic cylinder increases, which is then measured by one or more pressure sensors within the hydraulic cylinder and provided to one or more other devices, such as the lift electronic processor 210 or the controller electronic processor 310. In other embodiments, the load sensing device 3408 includes one or more strain or load sensors configured to sense the load or strain in the first connector 3404. In some examples, the strain or load sensors can be located on the second connector 3406 to detect the force applied to the second connector 3406 by the load. In still further examples, the load sensing device 2408 is a tension gauge applied to the first connector 3404 or the second connector 3406 to detect changes in tension of the connector. One or more sensors within the tension gauge can detect the amount of tension caused by the load and transmit that data to the lift electronic processor 210 or the controller electronic processor 310.

[0254] Now turning to Figure 35 , a system 3500 for determining a dynamic load of a lift 3502 is shown, in accordance with some embodiments. Dynamic load measurement allows for the determination of the size of a load while the load is in motion, such as when being lifted or lowered by the lift 3502. As shown, the lift 3502 is coupled to a load 3504 through a load connector 3506. It should be understood that the lift 3502 can be similar to the lift device 110 or other lift devices described herein. Further, the load connector 3506 can be a chain, cable, or other suitable connector for use with the lift 3502. Figure 35

[0255] To determine a dynamic load value, an electronic processor of the lift 3502, such as the lift electronic processor 21 described above, can compare the actual speed of the lift motor to the expected speed. The difference between the expected speed and the actual speed is directly proportional to the load. In some examples, the lift 3502 can control the motor to lift and lower the load 3504. The lift 3502 can control the speed of the motor by varying the duty cycle of the PWM period. For an unloaded condition, the electronic processor knows the expected speed for a given duty cycle (e.g., from experimental testing at the time of manufacture and storing the values in the lift memory 220). The electronic processor can also receive a speed feedback signal from the motor 250 (e.g., from an associated Hall sensor that provides a signal indicative of the speed of the motor). The electronic processor can then be configured to determine the difference between the expected speed (e.g., unloaded speed) and the actual speed to determine the size of the load.

[0256] ​In other examples, motor current can be used instead of motor speed. For example, the electronic processor can measure the current measured when raising and lowering the load at a given PWM duty cycle. The electronic processor can then correlate the current measured at the determined duty cycle to determine the magnitude of the load. In one example, the electronic processor can access a lookup table to determine the load magnitude based on the measured current and the determined PWM duty cycle applied to the motor. In some embodiments, the lifter 3502 can use only static measurements or dynamic measurements. However, in some embodiments, the lifter 3502 can use both static and dynamic load measurements to provide additional verification of the load magnitude.

[0257] Now turn Figure 36 , illustrates a smart load hook 3600 for use with a lifting apparatus, such as the lifting apparatus 110, according to some embodiments. The smart hook 3600 includes a hook mouth closure sensor 3602 and an electronics module 3604. The hook mouth closure sensor 3602 can be configured to provide an indication to one or more of the electronic processors described herein (e.g., the lift electronic processor 210 or the controller electronic processor 310) that the hook latch or hasp 3606 of the hook 3600 is closed, thereby securing the load. The hook mouth closure sensor 3602 can be in electronic communication with the electronics module 3604. The electronics module 3604 can include one or more sensors, such as a gyroscope, an accelerometer, etc. The electronics module 3604 can also include a wireless transmitter for communicating with one or both of the lifting apparatus 110 and the lift controller 120. The wireless transmitter can utilize Bluetooth, Bluetooth Low Energy ("BLE"), Wi-Fi, ZigBee, RF, 4G, 5G, IR, or any other suitable wireless communication protocol. In other examples, the electronics module 3604 may use a wired communication protocol to transmit data to one or both of the lift device 110 and the lift controller 120, or to other external devices.

[0258] Sensors in the smart hook 3600 can be configured to determine if the load is unbalanced. For example, the accelerometer and / or gyroscope of the electronic module 3604 can detect the orientation or movement of the smart hook 3600, which can indicate an imbalance in the load (e.g., the smart hook is not at the dead center of the load during the lift). This can be Figure 37As can be seen, where the load 3700 is off-center, causing movement in direction "A", which translates into lateral movement of the smart hook 3600. This movement can be detected by sensors within the electronics module 3604. The electronics module can transmit sensor data, along with mouth closure sensor data, to one or both of the lift device 110 and the lift controller 120, or other external devices, using the wireless transmitter of the electronics module 3604. In response, the lift device 110, the lift controller 120, or both, can take responsive action, such as stopping the motor 250 or generating an alarm (e.g., causing an LED of the lift controller 120 or the lift device 110 to light up) to notify the user.

[0259] Figures 38 to 41 A back-up manual operation mechanism of the lift device 110 Figure 2A is shown. Figure 38 and Figure 39 An electromagnetic brake 122 attached to the output shaft 124 of the lift motor 250 is shown. The electromagnetic brake 122 can be controlled by the user through the lift controller 120. The electromagnetic brake 122 includes a hub 128 around the output shaft 124, a set screw 132 coupling the hub 128 to the motor shaft 124, a pressure plate 136, a friction disc 142, an armature 146, a magnet 148, and a coil 152 within the magnet 148. When the lift device 110 is powered off or the electromagnetic brake 122 is engaged, the armature 146 is pushed against the friction disc 142 by a biasing member 156 (e.g., a coil spring) to restrict movement of the output shaft 124.

[0260] When the lift device 110 is powered on, a magnetic flux is formed between the coil 152, the magnet 148, and the armature 146 to compress the biasing member 156 so that the armature 146 disengages from the friction disc 142. As a result, an air gap 158 is formed between the armature 146 and the friction disc 142 to allow the output shaft 124 to rotate. In some embodiments, the electromagnetic brake 122 can include an override mechanism 162 operably coupled to the armature 146 to allow the user to manually close the armature 146 to disengage the electromagnetic brake 122. For example, the override mechanism 162 can be a lever integrated with the electromagnetic brake assembly 122, or can be adjusted using a screwdriver or other tool. Manually disengaging the electromagnetic brake 122 can allow the user to adjust the length of the chain 115 to adjust the positioning of a workpiece (e.g., a pallet) coupled to the chain 115 when the lift motor 250 is deactivated. Figure 1

[0261] Figure 40 and Figure 41 ​A hand-operated mechanism 164 is shown that can be coupled to the output shaft 124 of the lift motor 250. The hand-operated mechanism 164 includes an output device 168 that moves the chain 115, a hand wheel 172 operably coupled to the output device 168 via a threaded shaft 176, and a ratchet 178 positioned between the threaded shaft 176 and the hand wheel 172. A second chain or lever 182 (e.g., a hand chain) is coupled to the hand wheel 172 to allow a user to rotate the hand wheel 172 relative to the output device 168. If the user wishes to manually adjust the position of the workpiece 130 attached to the chain 115, the user can grasp and pull the second chain 182, which causes the hand wheel 172 to rotate on the threaded shaft 176. As the second chain 182 drives up the shaft 176 (41.4), the second chain 182 disengages the hand wheel 172 from a slip clutch located between the output device 168 and the hand wheel 172, while the ratchet 178 remains stationary. As a result, the threaded shaft 176 rotates the output device 168 to lower the chain 115 to allow the user to manually adjust the length of the chain 115 via the second chain 182. If the user releases the second chain 182, the second chain 182 will stop moving and the ratchet 178 will engage with the motor shaft 124 to stop movement and suspend the workpiece 130 on the chain 115. In other embodiments, other tools can be used in place of the second chain 182 to manually adjust the positioning of the chain 115.

[0262] In some embodiments, a ratchet device (e.g., a ratchet sleeve) can be coupled to the hand-operated mechanism 164 to allow a user to manually adjust the position of the workpiece 130 attached to the chain 115, thereby eliminating the need to secure the second chain or lever 182 to the hand-operated mechanism 164. In some embodiments, the hand-operated mechanism 164 and / or the lift motor 250 can include a fitting to allow a user to couple a powered device or a hand crank to adjust the position of the workpiece 130 attached to the chain 115. The fitting can be various types of fittings, such as a square fitting, a hex fitting, a 12-point drive fitting, etc. By using a powered device or a hand crank connected to the fitting, the hand-operated mechanism 164 allows for lowering of the load even when power to the lift motor 250 is removed.

[0263] Figures 42 to 44C Automatic stop features of the lift device 110 are shown. The automatic stop features discussed below can be used together or separately from each other to automatically stop the lift device 110 when the chain 115 reaches the end of travel on either end. The automatic stop features can provide necessary detection of the end of the chain 115 for normal operation of the lift device 110 and in the event of a possible malfunction of the lift device 110 (e.g., if the motor 250 loses power during lifting).

[0264] As Figure 42As shown, the lift device 110 includes limit switches 186 positioned near each chain receiving opening 188 on the lift device 110. The chain 115 can include a stop 190 adjacent to each end of the chain 115 that interacts with the limit switches 186 to provide a signal to the lift device 110 that the chain 115 is approaching the end of its travel. When the lift device 110 receives the signal, the lift electronic processor 210( Figure 2B ) deactivates the lift motor 250. It should be understood that the limit switches 186 can include mechanical limit switches( Figure 43A and Figure 43B ), Hall effect sensors, distance measurements, speed measurements, etc. Further, the lift transceiver 230 can communicate with the lift controller 120 (e.g., a joystick controller (see Figure 20 and Figures 25A to 25C ), a smartphone (see Figure 24 ), a tablet, etc.) to alert the user that the limit switch 186 was actuated. The user can also adjust the sensitivity or configuration of the limit switch 186 through the lift controller 120. For example, the lift controller 120 can track the number of times the limit switch 186 is actuated to determine when the limit switch 186 should be repaired, replaced, or tested. The lift transceiver 230 can also communicate other warnings or alerts (e.g., low battery, speed, overload, etc.) to the lift controller 120 using devices such as LED indicators, buzzers, etc. Further, the lift controller 120 can allow the user to set a constant operating speed.

[0265] As shown in Figure 43A and Figure 43B , the limit switch 186 can be a mechanical limit switch that is used to detect the presence of an object (e.g., the stop 190) when physical contact is made between the object and the limit switch 186. The limit switch 186 can include a lever 192 that is moved to close a set of electrical contacts 194 when the stop 190 actuates the limit switch 186( Figure 43B ). The engagement of the lever 192 with the electrical contacts 194 completes a circuit that sends a signal to the lift electronic processor 210( Figure 2B ) to deactivate the lift motor 250.

[0266] In other embodiments, the limit switch 186 may be an electromechanical rotary limit switch that automatically stops travel upon reaching a set number of revolutions or rotational position. The lift device 110 may have a preset number of revolutions associated with the maximum distance the chain 115 can travel or the minimum distance the chain 115 can travel. In other embodiments, the limit switch 186 may detect the number of chain links to automatically stop the lift device 110 when a predetermined number of chain links has been detected. In some embodiments, the lift controller 120 or a separate device (e.g., a smartphone) is configured to communicate with the lift device 110 to set a travel limit for the chain 115. For example, a user may control the lift device 110 to move the chain 115 to a desired maximum limit (either an upper or lower limit), then press a button on the lift controller or device's user interface, resulting in the transmission of a signal to the lift device 110 to store the current chain 115 position as a limit (either a rotary encoder position or a chain link). Subsequently, during subsequent operation, the lift device 110 is configured to stop driving the motor 250 when the chain 115 reaches the previously set limit. A similar process can be used to set upper and lower limits.

[0267] In other embodiments, the limit switch 186 may include an ultrasonic pulse generator and a receiver. The ultrasonic pulse generator may be configured to emit ultrasonic pulses along the length of the chain. The ultrasonic pulses may return to the ultrasonic receiver after reaching the end of the chain, and the return time may be measured and used to determine the length of the chain between the lifting device 110 and the end 115 of the chain. In other embodiments, changes in the frequency of the ultrasonic pulses may be used to determine the remaining length of the chain 115. In one embodiment, the limit switch 186 may be a time-of-flight ("ToF") sensor configured to detect the time of flight of a signal from the lifting device 110 to the end of the chain. In one embodiment, the time-of-flight sensor may be a laser or ultrasonic time-of-flight sensor. For example, a laser transmitter on the lifting device 110 may be configured to emit a laser output that is received by a receiver at the end of the chain. The ToF sensor may be configured to determine the length of the chain based on the measured time of flight of the laser signal. In other embodiments, the ToF sensor is a radio TOF sensor. The lifting device 110 may have a radio transceiver that communicates with a second radio transceiver located at the end of the chain 115. Radio signals may be sent and received from both radio transceivers, and the associated time of flight of the signal to be received after being sent (or sent and then received) may be used to determine the length of the chain 115 .

[0268] In further embodiments, the limit switch 186 may include a weight sensor to weigh the unloaded length of the chain 115. For example, a storage device such as a bag may hold excess (unloaded) chain 115. The limit switch 186 may measure the weight of the chain in the storage device and determine the loaded and unloaded lengths of the chain 115 based on the weight.

[0269] like Figure 44A and Figure 44B As shown, the limit switch 186 may be a reed switch ( Figure 44A ) or Hall sensor ( Figure 44B In such an embodiment, the chain 115 may include a magnetic device attached to each end of the chain 115 to generate a magnetic field. For example, the stopper 190 may be configured to include a magnet. As a result, when the end of the chain 115 comes close to the reed switch or Hall sensor and is acted upon by the magnetic field, the reed switch or Hall sensor is used to detect the nearby end of the chain 115 and send a signal to the lift electronic processor 210 ( Figure 2B ) to disable the lifting motor 250.

[0270] In other embodiments, Figure 44C As shown, the lifting device 110 can include a hard stop or overload limiting clutch 196 coupled to the output shaft 124. The clutch 196 can include a sprocket 198 operably coupled to the output shaft 124. In some embodiments, the sprocket 198 can be connected to an output device that drives the chain 115. When the chain 115 suddenly stops or strikes the body of the cordless lifting device 110, the clutch 196 detects an overload condition that causes the output shaft 124 to slip relative to the sprocket 198 (e.g., the sprocket 198 continues to rotate). In other embodiments, the output shaft 124 can be connected to an output device that drives the chain 115. Thus, when the clutch 196 detects an overload condition, the sprocket 198 slips relative to the output shaft 124 (e.g., the output shaft 124 continues to rotate). In either case, the slippage between the output shaft 124 and the sprocket 198 causes the chain 115 to stop rising or falling.

[0271] In some examples, other automatic stopping devices can be used with the lift device 110. In one example, the chain 115 can be painted, coated, or otherwise made to have a different color near the end of the chain 115. A sensor within the lift device 110, such as an imaging sensor, infrared sensor, or other sensor, can be configured to detect the color change and stop operation of the lift device 110 before reaching the end of the chain. In other implementations, the end of the chain 115 can be a different size (e.g., larger or smaller links), which can be detected by the lift device 110 and subsequently cause the lift device 110 to stop before reaching the end of the chain.

[0272] Figures 45 to 47 A lift controller 120 is shown attached to the lift device 110 via a retractable cord 202. The cord 202 can be attached to the lift device 110 by a rotatable spool 206 on the lift device 110. A user can adjust the length of the cord 202 relative to the lift device 110. As a result, the length of the cord 202 can be adjusted to account for different mounting heights of the lift device 110 when the lift device 110 is attached to the support surface 140. Furthermore, the cord 202 can be retracted and wound on the spool 206 when the lift device 110 is not in use.

[0273] Referring to Figure 45 and Figure 46 , the power source 240 of the lift device 110 can be coupled to the lift controller 120. As a result, the user can remove and replace the power source 240 (e.g., with another fully charged power source 240) while the lift device 110 remains suspended on the support surface 140.

[0274] In other implementations, as shown in Figure 47 and Figure 48 , the power source 240 can be coupled to the lift device 110 and housed thereon. As a result, the weight of the power source 240 is supported by the lift device 110, resulting in a reduced weight of the controller 120. The lift device 110 can include a power source storage area 242 Figure 48 to secure and enclose the power source 240 within the lift device 110. The power source storage area 242 includes a door 212 pivotally connected to the lift body to allow a user to selectively access the power source 240 (e.g., to replace the power source 240). The door 212 protects the power source 240 from the environment while the lift device 110 is in operation.

[0275] Referring to Figure 49 , the lift device 110 can also include a regenerative braking mechanism 216 for use with the lift motor 250. The regenerative braking mechanism 216 includes a power converter 218 that converts kinetic energy generated during operation of the lift device 110 into electrical energy that can be stored in the power source 240. For example, Figure 49 The flow of power through the lifting device 110 using the regenerative braking mechanism 216 is shown. When the motor shaft 124 rotates the chain 115 of the lifting device 110 to lower the suspended workpiece 130, Figure 2A ), the regenerative braking mechanism 216 can use the kinetic energy of the workpiece 130 to drive the power converter 218 to reduce its speed as the workpiece 130 descends, which in turn generates power to be stored in the power source 240. In some embodiments, the lifting device 110 can include a separate bank of capacitors that is operably coupled to the power source 240 to store energy. The regenerative braking mechanism can reduce heat loss, increase the efficiency of the lifting device 110, and reduce the wear and tear of mechanical braking components to extend the life of the components. The power converter 218 can be, for example, a generator in which a rotating motor shaft driven at least in part by the gravitational force of the traction load drives a rotor of the generator, which induces a current in a stator. The induced current is then provided to the battery bank 240 or the bank of capacitors.

[0276] To prevent uncontrolled descent of the workpiece 130 after the motor 250 is powered off (e.g., the battery is dead), the lifting device 110 includes a redundancy and failsafe system to allow safe lowering of the load. Turning now to Figure 50 , an inertia lock device 5000 is shown. The inertia lock device 5000 is configured to stop the rotation of the lifting motor 250, the transmission, or the output shaft of the lifting device 110 when the inertia of the load exceeds a predetermined value. The predetermined value can be set such that the inertia lock device 5000 engages when the load is determined to be free-falling. As Figure 50 shown, the inertia lock device 5000 is a mechanical device. However, in some embodiments, the inertia lock device 5000 can be an electronic inertia lock device 5000 that includes one or more inertia sensors coupled to an electronically activated inertia lock.

[0277] Turning now to Figure 51 , cam locks 5100 can be installed on the chain 115 or cable to prevent the load from free-falling. The cam locks 5100 can be configured to apply a force to the chain 115 and / or cable when the load is descending at a speed sufficient to engage the cam locks 5100. When the cam locks 5100 are engaged, they prevent additional cable or chain from passing through the cam locks 5100, thereby stopping its motion. To disengage the cam locks 5100, the load must be lifted slightly and then lowered at a speed lower than the engagement speed of the cam locks 5100. In some embodiments, the cam locks 5100 are connected to the lifting device 110. However, in other embodiments, the cam locks can be coupled to a support structure external to the lifting device 110.

[0278] Figure 52AA mechanical ratchet / clutch system 5200 is shown. The mechanical ratchet / clutch system 5200 includes a ratchet 5202 coupled to a drive shaft 5204 of the lift 110. However, in some examples, the ratchet 5202 can be coupled to other stages of the drive train or the output of the lift 110. The ratchet / clutch system 5200 also includes a pawl 5206 configured to engage with the ratchet. The pawl 5206 is configured to engage with the ratchet 5202 to prevent rotation of the shaft 5204 in a first direction. The first direction is the direction associated with lowering the load. In some implementations, the pawl 5206 engages the ratchet 5202 unless disengaged, thereby preventing movement of the drive shaft 5204. The ratchet / clutch system 5200 can also be used to prevent free fall of the lift 110 during loss of power or other situations.

[0279] Figure 52B A bidirectional ratchet clutch 5250 is shown, which locks in the opposite direction of the direction of load movement. The bidirectional ratchet clutch has a first ratchet 5252 and a second ratchet 5254. The first ratchet 5252 engages with a first pawl 5256, and the second ratchet 5254 engages with a second pawl 5258. Depending on the direction of load movement, the associated ratchet 5252, 5254 moves in the direction of the load, but the other ratchet 5252, 5254 is locked to prevent movement of the load in the opposite direction. In the case of a stationary load, both ratchets 5252, 5454 are locked, for example by rotating a direction lever in one direction, or by a solenoid (not shown). In one implementation, the ratchets 5252, 5254 are mounted on the drive shaft of a lift motor. However, in some examples, the ratchets can be mounted on any part of the drive train. This mechanism can prevent movement of the load in the case of a power outage of the lift by mechanically locking the drive shaft.

[0280] In some implementations, the ratchet clutches 5200, 5250 described above can be coupled to one or more sprockets within the lift 110 that are coupled to the drive shaft. In some implementations, the ratchet clutches 5200, 5250 can be coupled to the final sprocket that is directly connected to the chain holding the load, as described above. Thus, in the event of a drive shaft failure (e.g., drive shaft loosening, etc.), the ratchet clutches 5200, 5250 engage the final sprocket to prevent movement of the load.

[0281] Figure 53A solenoid-based locking system 5300 is shown to prevent the load from descending when the hoist 110 is powered off. The solenoid-based locking system 5300 uses a solenoid 5301 to drive a pin 5302 that interfaces with a slot or hole 5304 in a drive shaft 5306 to prevent the drive shaft 5306 from moving. In one embodiment, the solenoid 5301 can be configured to remove the pin 5302 from the slot or hole 5304 in the drive shaft 5306 when power is applied to the solenoid 5301. Thus, when the solenoid 5301 is powered off, the pin 5302 is released, causing interaction with the slot or hole 5304 in the drive shaft 5306, thereby preventing the load from moving when powered off.

[0282] Figure 54 A ratchet mechanism 5400 is shown that can be used to manually lower or raise the load of the hoist 110 in the event of a loss of power. A manual ratchet handle 5402 can be attached to a ratchet input 5404 of the hoist 110. A user can manually actuate the manual ratchet handle 5402 to raise or lower the load. In one embodiment, the ratchet input 5404 can be coupled to one or more gears within the hoist 110 to allow force reduction so that the user can easily manipulate the load through the manual ratchet handle.

[0283] In some embodiments, the hoist 110 can include a transmission, as described above, that has a high enough gear reduction ratio so that the friction created by the gear arrangement is not overcome by the load attached to the hoist. In other embodiments, the hoist 110 can use a continuous drive train to eliminate clutches that can be prone to failure during operation. As Figure 55 shown, in some embodiments, the hoist can incorporate a worm gear 5500 between a drive shaft 5502 and a load 5504. The worm gear transmission is configured to prevent backdriving or free rotation of the system by ensuring that the worm gear transmission is in constant contact with a main drive gear 5506 so that the main drive gear cannot move without a corresponding movement of the worm gear 5500. In some embodiments, a separate worm gear drive motor can be used to control the movement of the worm gear.

[0284] As described above, it is important to ensure that when a remote control or other safety sensor within the hoist system (e.g., the hoist 110) sends a stop command, the hoist stops and the load must stop as soon as possible. In some embodiments, a mechanical brake can be used to stop the operation of the hoist 110. For example, a friction brake, a ratchet brake (similar to those shown in FIGS. 15A and 15B above), a disc brake, etc. can be used to brake the hoist, e.g., by preventing operation of the drive shaft of the motor. Figure 52A and Figure 52B

[0285] As Figure 56 ​As shown, the electromechanical brake 5600 can be used to stop movement of the lift 110 and hold the load stationary. In one embodiment, the electromechanical brake 5600 can be placed on a drive shaft of the motor (e.g., the drive shaft 5204 described above). The electromechanical brake 5600 can include a brake field region 5602, an armature 5604, and a friction material 5606. Based on the configuration of the electromechanical brake, the friction material 5606 is brought into contact with the motor shaft based on movement of the armature 5604. In one embodiment, when power is applied to the brake field region 5602, the armature 5604 moves in response to a magnetic repulsion force to bring the friction material 5606 into contact with the drive shaft, thereby limiting or preventing movement of the drive shaft. In some embodiments, when no power is applied to the brake field region 5602, the armature 5604 can be biased to place the friction material 5606 in contact with the drive shaft. Thus, when power is applied to the brake field region 5602, the armature 5604 moves toward the brake field region 5602 based on a magnetic attraction force. In one embodiment, power applied to the motor is transmitted through the electromagnetic brake 5600 such that if the motor loses power, the armature 5604 is released to cause the friction material 5606 to contact the drive shaft and prevent movement of the drive shaft during power loss.

[0286] In some examples, the braking mechanisms (such as those described above) can be controlled through a remote control (e.g., the remote control 2000). In one embodiment, the remote control 2000 can be configured to send a plurality of redundant brake commands when a brake input is received from a user. The redundant brake commands can then be provided to a controller (e.g., the lift controller 120 as described above) as described above.

[0287] Turning now to Figure 57 FIG. 27 shows a flowchart illustrating a process 5700 for modifying operation of a lift (such as the lift 110) when conditions outside of normal operating conditions are determined, in accordance with some embodiments. At process block 5702, the lift 110 is operated in a normal operating mode. At process block 5704, a controller (e.g., the lift controller 120) determines whether one or more operating parameters exceed various thresholds indicative of an undesirable operating condition. In one embodiment, the operating parameters can be force and / or current parameters. The lift controller 120 can determine whether the force / current parameters experience a sudden spike or an increase in measured load above a predetermined threshold, indicating a possible increase in load (e.g., if contact is made with another object during lift operation). In other examples, the lift controller 120 determines whether the force / current parameters fall below a minimum threshold, indicating a sudden decrease in load. In other embodiments, the lift controller 120 evaluates various other operating parameters, such as those described above, to determine whether the operating parameters exceed various thresholds.

[0288] In response to determining that the measured parameter does not exceed one of the predetermined thresholds, the lift controller 120 continues operation of the lift device 110 at process block 5702. In response to determining that the measured parameter does exceed one of the predetermined thresholds, the operation of the lift device is modified at process block 5706. In one example, when the force / current parameter is determined to exceed a threshold indicative of a sudden increase in load, the lift controller 120 stops operation of the lift device 110. In some embodiments, the lift controller 120 stops operation of the lift device for a predetermined period of time, such as one minute. However, predetermined periods of time greater than one minute or less than one minute are also contemplated. In other embodiments, the lift controller 120 stops operation of the lift device until the lift controller 120 receives a user override. Similarly, the lift controller 120 can stop operation of the lift device 110 in response to the force / current parameter being determined to be below a predetermined threshold. In other embodiments, the lift controller 120 can retract the load a predetermined amount to mitigate the potentially jarring or pinching load. For example, the lift controller 120 can control the lift device 110 to retract the load six inches. However, retraction distances greater than six inches or less than six inches are also possible. After the lift device retracts the load a predetermined amount, the load controller 120 can again evaluate one or more operational parameters, such as those described above, to determine whether the adverse operating condition has been resolved. If the measured operational parameters still exceed the predetermined thresholds, the lift controller 120 can instruct the host device 110 to stop.

[0289] Turning now to Figure 58, a lift device (e.g., lift device 110) is shown attached to the load 5800. The lift device 110 can be configured to receive one or more voice commands to control the operation of the lift device 110. In one implementation, a microphone or audio input on the lift controller 120 receives the voice commands. In other implementations, the microphone can be coupled to a remote control (e.g., remote control 2000 described above). In still further implementations, the microphone can be remote from the lift device, such as a microphone worn by the user. In other examples, the microphone can be integrated into a user device, such as a smart phone, smart watch, or other personal electronic device. In one implementation, the user must repeat the command within a specified time frame to maintain the current mode of operation of the lift device 110. For example, if the user wishes to lift the load upward, the user would issue a voice command such as "up." To maintain the upward motion, the user would need to reissue the voice command within a predetermined time period (e.g., three seconds). However, time periods greater than three seconds and less than the predetermined time period are also possible. In response to the user not issuing a subsequent command within the predetermined time period, the lift device 110 will stop (e.g., hold the load in the current position). This is the same for all voice commands, except for the "stop" command, which will maintain its state (e.g., stopped) until a subsequent command is issued. Example voice commands can include up, down, stop, float, and the like.

[0290] Turning now to Figure 59 , a motion-activated lift system 5900 is shown in accordance with some implementations. The motion-activated lift system 5900 includes a lift device (e.g., lift device 110). The lift device can include one or more sensing devices 5902 that are used to detect the motion of a user, such as their hands, arms, legs, and the like. In one implementation, the one or more sensing devices can include time-of-flight (ToF) sensors, camera sensors, IR sensors, or other applicable sensing devices. The sensing devices 5902 can be in communication with a controller (e.g., lift controller 120 described above). The sensing devices 5902 are configured to interpret the motion of the user as a lift command. For example, a user can move their hand or arm upward to provide an "up" command. Similarly, a user can move their hand or arm downward to provide a "down" command. Based on the sensed motion provided by the user and sensed via the sensing devices 5902, the lift controller 120 is configured to control the operation of the lift device 110. While up and down commands are described above, it is contemplated that a number of other gesture commands can be used to control other operations of the lift.

[0291] Turning now to Figure 60FIG. 6 shows a chain control hoist system 6000, according to some embodiments. The hoist system 6000 can include a hoist (such as the hoist 110 described above). The hoist system 6000 also includes a load chain 6002 with one or more embedded sensors 6004 for sensing a user touching or moving the load chain 6002. In one example, the embedded sensors 6004 are one or more of capacitive sensors, inductive sensors, etc. In one embodiment, the embedded sensors 6004 are in communication with a controller (such as the hoist controller 120 described above). The sensors can be configured to sense a user manipulating the chain with their hands or other limbs. Manipulating the chain can include jerking, shaking, pushing, pulling, or otherwise moving the chain to indicate that the user wants the hoist 110 to stop. This can allow a user to stop the hoist 110 by moving the chain in situations where it is not convenient to operate controls on a remote, such as in the case of an emergency stop (“E-STOP”). By using inductive or capacitive sensors, inadvertent movement of the load chain does not itself cause the hoist 110 to stop. Rather, the sensors must first determine the touch of a person by the embedded sensors 6004.

[0292] Turning now to Figure 61 FIG. 6 shows a chain control hoist system 6000, according to some embodiments. The hoist system 6000 can include a hoist (such as the hoist 110 described above). The hoist system 6000 also includes a load chain 6002 with one or more embedded sensors 6004 for sensing a user touching or moving the load chain 6002. In one example, the embedded sensors 6004 are one or more of capacitive sensors, inductive sensors, etc. In one embodiment, the embedded sensors 6004 are in communication with a controller (such as the hoist controller 120 described above). The sensors can be configured to sense a user manipulating the chain with their hands or other limbs. Manipulating the chain can include jerking, shaking, pushing, pulling, or otherwise moving the chain to indicate that the user wants the hoist 110 to stop. This can allow a user to stop the hoist 110 by moving the chain in situations where it is not convenient to operate controls on a remote, such as in the case of an emergency stop (“E-STOP”). By using inductive or capacitive sensors, inadvertent movement of the load chain does not itself cause the hoist 110 to stop. Rather, the sensors must first determine the touch of a person by the embedded sensors 6004.

[0293] Turning now to Figure 62 FIG. 6 shows a chain control hoist system 6000, according to some embodiments. The hoist system 6000 can include a hoist (such as the hoist 110 described above). The hoist system 6000 also includes a load chain 6002 with one or more embedded sensors 6004 for sensing a user touching or moving the load chain 6002. In one example, the embedded sensors 6004 are one or more of capacitive sensors, inductive sensors, etc. In one embodiment, the embedded sensors 6004 are in communication with a controller (such as the hoist controller 120 described above). The sensors can be configured to sense a user manipulating the chain with their hands or other limbs. Manipulating the chain can include jerking, shaking, pushing, pulling, or otherwise moving the chain to indicate that the user wants the hoist 110 to stop. This can allow a user to stop the hoist 110 by moving the chain in situations where it is not convenient to operate controls on a remote, such as in the case of an emergency stop (“E-STOP”). By using inductive or capacitive sensors, inadvertent movement of the load chain does not itself cause the hoist 110 to stop. Rather, the sensors must first determine the touch of a person by the embedded sensors 6004.

[0294] Accordingly, various embodiments described herein provide a wireless hoist system. Various features and advantages are set forth in the following claims.

Claims

1. A wireless lifting system comprising: a first lifting device comprising a first motor and a first wireless transceiver; a second lifting device comprising a second motor and a second wireless transceiver, wherein the first lifting device and the second lifting device are configured to be coupled to a workpiece to lift or lower the workpiece; as well as a controller configured to wirelessly communicate with the first wireless transceiver of the first lifting device and the second wireless transceiver of the second lifting device, the controller configured to: Receive user input, determining a first operating parameter and a second operating parameter based on the user input, and wirelessly providing a first control signal indicative of the first operating parameter to the first lifting device, wirelessly providing a second control signal indicative of the second operating parameter to the second lifting device, and receiving a level input from a level sensor coupled to the workpiece and configured to indicate an angle of the level sensor relative to the ground; wherein the first lifting device is configured to operate based on the first control signal and the horizontal input, and Wherein, the second lifting device is configured to operate based on the second control signal and the horizontal input.

2. The wireless lifting system according to claim 1, wherein: The controller is configured to communicate with the first lifting device via a first wireless channel, and wherein the controller is configured to communicate with the second lifting device via a second wireless channel.

3. The wireless lifting system according to claim 1, further comprising a third lifting device, wherein the first lifting device is further configured to: determining a third operating parameter based on the first operating parameter; and providing a third control signal indicative of the third operating parameter to the third lifting device, The third lifting device is configured to operate based on the third control signal.

4. The wireless lifting system according to claim 3, wherein: The controller is configured to communicate with the first lifting device via a first wireless channel, and wherein the first lifting device is configured to communicate with the third lifting device via a second wireless channel.

5. The wireless lifting system according to claim 1, wherein: The first lifting device further includes: a chain connectable to the workpiece to lift and lower the workpiece, the first motor coupled to the chain to release and retract the chain; a sensor for detecting a chain length of the chain, the chain length of the chain indicating a length of the chain released from the first lifting device; and a motor driver coupled to the sensor and the first motor and configured to: receiving the chain length from the sensor, receiving a first control signal from the controller, and The first motor is driven according to the first control signal and the chain length.

6. The wireless lifting system according to claim 1, wherein: The first operating parameters include one or more selected from the group consisting of: speed, direction, and chain length.

7. The wireless lifting system according to claim 1, wherein: The user input is a desired movement of the workpiece.

8. The wireless lifting system according to claim 1, wherein: The user input includes a position of the first lifting device, a position of the second lifting device, and a desired end position of the workpiece.

9. A wireless lifting system comprising: a first lifting device comprising a first motor and a first wireless transceiver; a second lifting device comprising a second motor and a second wireless transceiver, wherein the first lifting device and the second lifting device are configured to be coupled to a workpiece to lift or lower the workpiece; wherein the first lifting device is coupled to the workpiece via a first chain, and the second lifting device is coupled to the workpiece via a second chain; and a controller configured to wirelessly communicate with the first wireless transceiver of the first lifting device and the second wireless transceiver of the second lifting device, the controller configured to: Receive user input, determining a first operating parameter based on the user input, wirelessly providing a first control signal indicative of the first operating parameter to the first lifting device, and wirelessly providing a second control signal indicative of the first operating parameter to the second lifting device, wherein the first lifting device is configured to operate based on the first control signal, wherein the second lifting device is configured to operate based on the second control signal; and The first lifting device further comprises: a sensor for detecting a chain length of the first chain, the chain length indicating a length of the first chain released from the first lifting device; and a motor driver coupled to the sensor and the first motor and configured to: receiving the detected chain length from the sensor; receiving a first control signal from the controller; and The first motor is driven according to the first control signal and the chain length.

10. The wireless lifting system according to claim 9, wherein: The first control signal is provided to the first lifting device in response to the controller determining that a first wireless channel associated with the first lifting device is enabled, and wherein the second control signal is provided to the second lifting device in response to determining that a second wireless channel associated with the second lifting device is enabled.

11. The wireless lifting system according to claim 9, further comprising: a third lifting device comprising a third motor; and a third wireless transceiver; wherein the third host device is associated with the third wireless channel; as well as The controller is further configured to: determining whether the third wireless channel is disabled, and In response to determining that the third wireless channel is disabled, not providing a control signal indicative of the first operating parameter to the third lifting device.

12. A wireless lifting system comprising: a first lifting device having a first motor and a first wireless transceiver; a second lifting device having a second motor and a second wireless transceiver, wherein the second wireless transceiver communicates wirelessly with the first wireless transceiver, and the first lifting device and the second lifting device are configured to be coupled to a workpiece to lift or lower the workpiece; a controller that wirelessly communicates with the first wireless transceiver of the first lifting device, wherein the controller is configured to: receiving a level input from a level sensor coupled to the workpiece and configured to indicate an angle of the level sensor relative to the ground; receiving a user input and determining a first operating parameter based on the user input and the level input, wirelessly providing a first control signal indicative of the first operating parameter to the first lifting device, wirelessly providing a second control signal to the second lifting device, wherein the second control signal is based on the first control signal, and The first lifting device operates according to the first control signal, and the second lifting device operates according to the second control signal.

13. The lifting system according to claim 12, wherein: The first wireless transceiver, the second wireless transceiver, and the controller communicate via a radio frequency communication protocol, wherein the radio frequency communication protocol uses dual identifiers, one broadcast from the controller and a separate identifier for each of the first wireless transceiver and the second wireless transceiver.

14. The lifting system according to claim 13, wherein: The radio frequency communication protocol initiates pairing between the controller and the first wireless transceiver, and the lifting system is configured to: broadcasting a first pairing signal from the controller to the first wireless transceiver, wherein the first pairing signal includes an identifier of the controller, storing an identifier of the controller in the first wireless transceiver, In response to receiving the pairing signal, the first wireless transceiver transmits an identifier of the first wireless transceiver, storing an identifier of the first wireless transceiver in the controller, and A pairing identifier including at least an identifier of the controller and an identifier of the first wireless transceiver is generated for use in performing future communications between the controller and the first wireless transceiver.

15. The lifting system according to claim 14, wherein: The radio frequency communication protocol initiates pairing between the controller and the second wireless transceiver, and the lifting system is configured to: broadcasting a second pairing signal from the controller to the second wireless transceiver, wherein the second pairing signal includes an identifier of the controller, storing an identifier of the controller in the second wireless transceiver, In response to receiving the pairing signal, the second wireless transceiver transmits an identifier of the second wireless transceiver, storing an identifier of the second wireless transceiver in the controller, and A pairing identifier including at least an identifier of the controller and an identifier of the second wireless transceiver is generated for use in performing future communications between the controller and the second wireless transceiver.

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