Air lift inclination adjustment system

Abstract

The present disclosure provides, among other things, a tilt adjustment system and method for preventing aerial lifts from tipping over during operation. An aerial lift equipped with such a system is also provided. The tilt adjustment system includes a plurality of sensors, including at least a tilt sensor and a lower boom sensor, or real-time measurements of the chassis angle and lower boom angle and communicate these values to a control module that correspondingly controls hydraulic enable valves. The tilt adjustment system also additionally includes a boom rack with a mechanical stow switch.

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 211,813, filed June 17, 2021, which is incorporated herein by reference in its entirety. Technical Field

[0003] This disclosure generally relates to the field of aerial lifts, and particularly to the safe operation of such lifts. More specifically, this disclosure provides tilt adjustment systems and methods for preventing aerial lifts from tipping over during operation. Background Technology

[0004] Aerial lifts are commonly used in the power industry to facilitate work at higher positions, such as utility poles, telephone or power lines, streetlights, and building walls. Beyond the traditional power industry, aerial lifts are also widely used in fields such as construction, emergency rescue, and the film industry. These aerial lifts typically feature a work platform (e.g., a bucket-shaped workstation) connected to a wheeled vehicle via a multi-section boom. This boom is adapted to lift and orient the aerial platform, which carries personnel to perform the necessary tasks. Workers typically control the lift's operation from the aerial platform or bucket via a control unit connected to the bucket and containing several handles that can be used to manipulate the bucket's position and orientation by controlling the boom sections, etc.

[0005] Many factors need to be considered for the safe operation of aerial lifts, including weather conditions (such as snow, ice, and wind), ground conditions (such as firm or soft ground), and whether the surface is sloping or level. Of all the potential hazards, overturning is one of the most serious accidents that can occur during aerial lift operation. Therefore, aerial lifts should be operated with restrictions when working on sloping surfaces due to overturning stability, operational, or structural limitations. However, there is currently no way to determine the exact limitations under different operating conditions (i.e., different angles of inclination), which greatly limits the safe application of aerial lifts.

[0006] Therefore, a safe operating system is needed that can guide aerial elevators operating on inclined surfaces. Summary of the Invention

[0007] This disclosure provides a tilt control system that can measure the tilt angle of the ground on which the aerial elevator is operating, and, if necessary, can further limit horizontal extension via a lower boom raising function.

[0008] Therefore, one aspect of this disclosure relates to a tilt adjustment system for the safe operation of an aerial lift, the aerial lift including a base on a movable chassis, a turntable connected to the top of the base and capable of horizontal rotation, a lower boom having a first end connected to the upper end of the turntable and capable of vertical rotation, an elbow joint (knuckle) connecting a second end of the lower boom to a first end of an extendable upper boom, and an aerial work platform connected to the second end of the upper boom. The tilt adjustment system includes: a plurality of sensors, including at least a tilt sensor and a lower boom sensor, wherein the tilt sensor is located at the bottom of the turntable and measures the chassis angle in real time, the chassis angle being the angle of the chassis relative to a horizontal surface. A lower boom sensor is located on the lower boom and measures the lower boom angle in real time, which is the angle of the lower boom relative to the chassis surface; a hydraulic enable valve is located in the turntable and operably connected to a hydraulic control valve located in the base, which can raise or lower the lower boom, wherein the lower boom can only be raised when the hydraulic enable valve is opened; a control module receives real-time values ​​of the chassis angle and the lower boom angle measured by the tilt sensor and the lower boom sensor, respectively, and opens or closes the hydraulic enable valve based on the received values ​​and an algorithm; and a boom bracket is vertically mounted to the movable chassis and has a mechanical retraction switch on its top, which stops the tilt sensor from measuring / updating the chassis angle when the mechanical retraction switch is closed.

[0009] Another aspect of this disclosure relates to a method for preventing an aerial lift from tipping over during operation, the aerial lift including a base on a movable chassis, a turntable connected to the top of the base and capable of horizontal rotation, a lower boom having a first end connected to the upper end of the turntable and capable of vertical rotation, an elbow joint connecting a second end of the lower boom to the first end of an extendable upper boom, and an aerial work platform connected to the second end of the upper boom, the method comprising: a) measuring a chassis angle, the chassis angle being the angle of the chassis relative to a horizontal surface: i. if the If the measured chassis angle exceeds the maximum operating chassis angle, the lower boom is locked in its retracted position; or ii. if the measured chassis angle does not exceed the maximum operating chassis angle, the maximum operating lower boom angle is determined based on the measured chassis angle; and b) measure the lower boom angle, which is the angle of the lower boom relative to the chassis surface: i. when the measured lower boom angle is less than the maximum operating lower boom angle, enable the lower boom raising function; and ii. when the measured lower boom angle reaches the maximum operating lower boom angle, disable the lower boom raising function.

[0010] This disclosure also includes an aerial elevator equipped with the tilt adjustment system disclosed herein. Attached Figure Description

[0011] The following drawings are provided to illustrate, but not to limit, embodiments of the present disclosure, in order to facilitate further description of them.

[0012] Figure 1 Different operating states of the aerial lift equipped with the tilt adjustment system of this disclosure are shown. When operating on an inclined surface (upper panel), the raising of the lower boom is limited, while when operating on a horizontal surface (lower panel), the lower boom can be raised to its maximum capacity.

[0013] Figure 2 This is a perspective view of an aerial elevator equipped with a tilt adjustment system according to certain embodiments of the present disclosure.

[0014] Figure 3 yes Figure 2 An enlarged view of a portion of an aerial lift according to certain embodiments of the present disclosure, the portion including a boom frame with a mechanical retraction switch.

[0015] Figure 4 This is a perspective view of the tilt adjustment system described in this disclosure, excluding the hanger frame.

[0016] Figure 5 yes Figure 4 An enlarged view of a portion of the tilt adjustment system, which includes a control module, a hydraulic enable valve, and a tilt sensor. Detailed Implementation

[0017] Novel systems for the safe operation of aerial lifts and methods for preventing aerial lifts from tipping over during operation are provided and described. Aerial lifts equipped with such systems or implementing such methods are also provided and described. Various embodiments and modifications are possible and fall within the scope of this disclosure.

[0018] According to one aspect of this disclosure, a tilt adjustment system for safe operation of an aerial lift is provided. The aerial lift includes a base on a movable chassis, a turntable connected to the top of the base and capable of horizontal rotation, a lower boom having a first end connected to the upper end of the turntable and capable of vertical rotation, an elbow joint connecting a second end of the lower boom to a first end of an extendable upper boom, and an aerial work platform connected to the second end of the upper boom. The tilt adjustment system includes: a plurality of sensors, including at least a tilt sensor and a lower boom sensor, wherein the tilt sensor is located at the bottom of the turntable and measures the chassis angle in real time, the chassis angle being the angle of the chassis relative to a horizontal surface, and the lower boom sensor is located at... The system includes: a lower boom that measures the lower boom angle in real time, the lower boom angle being the angle of the lower boom relative to the chassis surface; a hydraulic enable valve located in the turntable and operably connected to a hydraulic control valve located in the base, which raises or lowers the lower boom, wherein the lower boom can only be raised when the hydraulic enable valve is opened; a control module that receives real-time values ​​of the chassis angle and the lower boom angle measured by the tilt sensor and the lower boom sensor, respectively, and opens or closes the hydraulic enable valve based on the received values ​​and an algorithm; and a boom bracket that is vertically mounted to the movable chassis and has a mechanical retraction switch on its top, which stops the tilt sensor from measuring / updating the chassis angle when the mechanical retraction switch is closed.

[0019] As used herein, a "horizontal surface" refers to a flat surface perpendicular to the plumb line. The term "horizontal surface" as used herein may be used interchangeably with the "horizontal plane" used in the normal operation of an industry-standard aerial lift. As used herein, a "horizontal plane" refers to a surface that is perpendicular to the plumb line or the direction of gravity at every point, or parallel to a still water surface. In some embodiments, the lower boom angle can be determined by measuring the orientation of the lower boom relative to the horizontal surface.

[0020] In some embodiments, the algorithm used by the control module is as follows: 1) If the received chassis angle value is equal to or greater than the maximum operating chassis angle, the hydraulic enable valve is closed, the lower boom is locked in its retracted position, and the mechanical retraction switch is opened; or 2) If the received chassis angle value is less than the maximum operating chassis angle, the mechanical retraction switch is closed and the lower boom is released from its retracted position. The control module determines the maximum operating lower boom angle based on the received chassis angle value: a) When the received lower boom angle value is less than the maximum operating lower boom angle, the hydraulic enable valve is opened, and b) When the received lower boom angle value reaches the maximum operating lower boom angle, the hydraulic enable valve is closed.

[0021] The maximum operating chassis angle varies depending on the model of the aerial lift. In some embodiments, the maximum operating chassis angle can be in the range of 7 to 10 degrees. In some embodiments, the maximum operating chassis angle is 10 degrees.

[0022] In some embodiments, when the received chassis angle value is equal to or less than a predetermined tilt value, the lower boom can be fully extended (raised) with a maximum operating lower boom angle of 90 degrees. That is, the air lift operating on an inclined surface with an angle not exceeding the predetermined tilt value is permitted to operate throughout its entire envelope as if it were operating on a horizontal surface. The predetermined tilt value varies depending on the air lift model. In some embodiments, the predetermined tilt value is 5 degrees.

[0023] In some embodiments, if the aerial lift is equipped with a suitable stabilizer assembly, the maximum operating chassis angle can exceed 10 degrees. As used herein, "stabilizer" or "extendant" can refer to auxiliary components (typically like legs) on wheeled vehicles that are deployed when stabilization is required, such as on cranes lifting heavy loads, or on aerial lifts as described in this disclosure. In some embodiments, aerial lifts equipped with stabilizers or extenders can increase the maximum operating chassis angle by up to 2 degrees.

[0024] For a specific aerial lift model, additional factors may also influence the maximum operating lower boom angle. Therefore, in some embodiments, the control module determines the maximum operating lower boom angle based on received chassis angle values ​​and additional parameters selected from the length and weight of the upper boom, the load on the aerial work platform, and combinations thereof. Other exemplary parameters may include, but are not limited to, the material of the lower and / or upper booms, the angle of the upper boom relative to the horizontal surface, the weight of the portion of the aerial lift below the base, and the overall weight distribution of the aerial lift.

[0025] In some embodiments, the system further includes an LED panel displaying the real-time status of the air lift. The status can be indicated in any suitable manner, such as color codes, graphics and / or text formats, or combinations thereof.

[0026] Another aspect of this disclosure relates to a method for preventing an aerial lift from tipping over during operation. The aerial lift includes a base on a movable chassis, a turntable connected to the top of the base and capable of horizontal rotation, a lower boom having a first end connected to the upper end of the turntable and capable of vertical rotation, an elbow joint connecting a second end of the lower boom to the first end of an extendable upper boom, and an aerial work platform connected to the second end of the upper boom. The method includes: a) measuring a chassis angle, which is the angle of the chassis relative to a horizontal surface: i. if the measured... If the chassis angle exceeds the maximum operating chassis angle, the lower boom is locked in its retracted position; or if the measured chassis angle does not exceed the maximum operating chassis angle, the maximum operating lower boom angle is determined based on the measured chassis angle; and b) measure the lower boom angle, which is the angle of the lower boom relative to the chassis surface: i) when the measured lower boom angle is less than the maximum operating lower boom angle, enable the lower boom raising function; and ii) when the measured lower boom angle reaches the maximum operating lower boom angle, disable the lower boom raising function.

[0027] In some embodiments, the maximum operating chassis angle is in the range of 7 to 10 degrees. In some embodiments, the maximum operating chassis angle is 10 degrees.

[0028] In some embodiments, the maximum operating boom angle is 90 degrees when the measured chassis angle is equal to or less than a predetermined tilt value. In some embodiments, the predetermined tilt value is 5 degrees.

[0029] In some embodiments, if the aerial elevator is equipped with a suitable stabilizer assembly, the maximum operating chassis angle can exceed 10 degrees.

[0030] In some embodiments, the maximum operating lower boom angle is determined based on the measured chassis angle and additional parameters selected from the length of the upper boom, the weight of the upper boom, the load of the aerial work platform, and combinations thereof.

[0031] In some embodiments, a set of sensors measures the chassis angle and the lower boom angle. The sensors used herein are not limited to any particular type or model. Each sensor may operate independently or in combination with other sensors.

[0032] In some embodiments, the angle of the lower boom is measured and monitored in real time to ensure that the aerial lift operates within a safe area.

[0033] This disclosure also includes an aerial elevator equipped with the tilt adjustment system disclosed herein.

[0034] The following discussion provides further examples illustrating this disclosure. These examples are merely illustrative and are not intended to limit the scope of this disclosure in any way.

[0035] refer to Figure 2 and Figure 3 A typical aerial lift 100 includes a movable chassis 1 (typically a motor vehicle such as a truck), a base 2 located on the movable chassis 1, a turntable 3 connected to the top of the base 2 and capable of horizontal rotation, a lower boom 4 (typically including a compensating link 401) having a first end 402 connected to the upper end 301 of the turntable 3 and capable of vertical rotation, an elbow joint 5 connecting the second end 403 of the lower boom 4 to the first end 601 of an extendable upper boom 6, and an aerial work platform 7 connected to the second end 602 of the upper boom 6. When the aerial lift 100 operates on a horizontal surface or an inclined surface having an angle equal to or less than a certain value (typically 5 degrees depending on the specific aerial lift model), the aerial lift is permitted to operate within its entire envelope, i.e., the lower boom 4 can be raised to its full extension range without the potential risk of overturning due to changes in the overall center of gravity of the aerial lift. When the tilt angle exceeds, for example, 5 degrees above a horizontal surface, and the aerial work platform is at its maximum horizontal position, it may exceed structural, functional, and overturning stability limits, meaning the risk of overturning increases significantly. The solution to this overturning risk is to limit the maximum elevation of the lower boom when operating on a tilted surface, such as... Figure 1 As shown in the image.

[0036] This disclosure provides a tilt adjustment system to implement this safety measure. (Reference) Figure 4 The system employs a set of angle sensors to help determine the limits on the lower boom raising function. Specifically, in some embodiments of this disclosure, a tilt sensor 8 may be mounted in the turntable 3 and measures in real time the angle between the chassis 1 and the horizontal surface (i.e., the chassis angle). The chassis angle corresponds to the tilt angle of the tilted surface relative to the horizontal surface. The real-time value of the chassis angle is sent to a control module 11 located in the turntable 3, which compares the chassis angle value with a predetermined maximum operating chassis angle. If the received chassis angle exceeds the maximum operating chassis angle, the control module 11 disables the raising (lifting) function of the lower boom 4 by closing a hydraulic enable valve 10, which is also located in the turntable 3 and operably connected to a hydraulic control valve 13 located in the base 2, and the lower boom 4 is locked in its retracted position, although in some cases, the upper boom 6 can operate freely. If the received chassis angle does not exceed the maximum operating chassis angle, a mechanical retraction switch 801 on the top of the boom frame 8 is closed. Figure 3 Furthermore, tilt sensor 8 stops measuring / updating chassis angle, and lower boom 4 and upper boom 6 are allowed to operate.

[0037] Return to reference Figure 4 Once the tilt sensor 8 stops updating the chassis angle, the control module 11 determines the maximum operating boom angle based on the last received chassis angle value. This creates a "safe zone" for the operation of the boom 4. A boom sensor 9 located on the boom 4 measures the boom angle in real time, which is the angle of the boom relative to the chassis surface (or equivalently, the surface on which the aerial lift is operating). The control module 11 receives this real-time boom angle and compares it to a predetermined maximum operating boom angle in which the boom 4 can be freely operated. Once the boom angle reaches the maximum operating boom angle, the control module 11 closes the hydraulic enable valve 10, thereby disabling the boom 4's raising function and preventing further raising. For ease of operation, in some embodiments of this disclosure, an LED panel 12 is also included in the tilt adjustment system. The operator can check this panel to monitor the status of the aerial lift and ensure operation is within the safe zone. Figure 5 An enlarged view focusing on tilt sensor 8, control module 11, and hydraulic enable valve 10 is provided.

[0038] Although exemplary embodiments of this disclosure have been described herein, it should be understood that this disclosure is not limited to those described, and various other changes or modifications can be made by those skilled in the art. For example, it should be understood that various omissions, substitutions, and changes can be made to the form and details of the systems and methods described and illustrated. In many suitable cases, the steps in the method may be performed in a different order. Further variations, modifications, and implementations will occur to those skilled in the art without departing from the scope or spirit of this disclosure.

Claims

1. A tilt adjustment system for safe operation of an aerial lift, the aerial lift comprising a base on a movable chassis, a turntable connected to the top of the base and capable of horizontal rotation, a lower boom having a first end connected to the upper end of the turntable and capable of vertical rotation, an elbow joint connecting a second end of the lower boom to the first end of an extendable upper boom, and an aerial work platform connected to the second end of the upper boom, the tilt adjustment system comprising: Multiple sensors, including at least a tilt sensor and a lower boom sensor, wherein the tilt sensor is located at the bottom of the turntable and measures the chassis angle in real time, the chassis angle being the angle of the chassis relative to a horizontal surface, and the lower boom sensor is located on the lower boom and measures the lower boom angle in real time, the lower boom angle being the angle of the lower boom relative to the chassis surface; A hydraulic enabling valve, located in the turntable and operably connected to a hydraulic control valve located in the base, the hydraulic control valve being capable of raising or lowering the lower boom, wherein the lower boom can only be raised when the hydraulic enabling valve is opened; The control module receives real-time values ​​of the chassis angle and the lower boom angle measured by the tilt sensor and the lower boom sensor, respectively, and opens or closes the hydraulic enable valve based on the received values ​​and an algorithm; and A boom bracket is vertically mounted to a movable chassis and has a mechanical retraction switch on its top. When the mechanical retraction switch is closed, the tilt sensor stops measuring / updating the chassis angle.

2. The tilt adjustment system according to claim 1, wherein, The algorithm is as follows: 1) If the received chassis angle value is equal to or greater than the maximum operating chassis angle, the hydraulic enable valve is closed, the lower boom is locked in its retracted position, and the mechanical retraction switch is opened. or 2) If the received chassis angle value is less than the maximum operating chassis angle, the mechanical retraction switch is closed and the lower boom is released from its retracted position. The control module determines the maximum operating lower boom angle based on the received chassis angle value. a) When the received lower boom angle value is less than the maximum operating lower boom angle, the hydraulic enable valve is opened, and b) When the received lower boom angle value reaches the maximum operating lower boom angle, the hydraulic enable valve is closed.

3. The tilt adjustment system according to claim 2, wherein, The maximum operating chassis angle is in the range of 7 to 10 degrees.

4. The tilt adjustment system according to claim 2, wherein, The maximum operating chassis angle is 10 degrees.

5. The tilt adjustment system according to claim 2, wherein, When the received chassis angle value is equal to or less than the predetermined tilt value, the maximum operating boom angle is 90 degrees.

6. The tilt adjustment system according to claim 5, wherein, The predetermined tilt angle is 5 degrees.

7. The tilt adjustment system according to claim 2, wherein, If the aerial elevator is equipped with a suitable stabilizer assembly, the maximum operating chassis angle can exceed 10 degrees.

8. The tilt adjustment system according to claim 2, wherein, The control module determines the maximum operating lower boom angle based on the received chassis angle value and additional parameters selected from the boom length, boom weight, overhead work platform load, and their combination.

9. The tilt adjustment system according to claim 1, further comprising an LED panel displaying the real-time status of the aerial elevator.

10. A method for preventing an aerial lift from tipping over during operation, the aerial lift comprising a base on a movable chassis, a turntable connected to the top of the base and rotatable horizontally, a lower boom having a first end connected to the upper end of the turntable and rotatable vertically, an elbow joint connecting a second end of the lower boom to a first end of an extendable upper boom, and an aerial work platform connected to the second end of the upper boom, the method being implemented based on the tilt adjustment system for safe operation of the aerial lift as claimed in claim 1, comprising: a) The chassis angle is measured using a tilt sensor; the chassis angle is the angle of the chassis relative to a horizontal surface. i) If the chassis angle received by the control module exceeds the maximum operating chassis angle, the hydraulic enable valve is closed, the lower boom is locked in its retracted position, and the mechanical retraction switch remains open, or ii) If the chassis angle received by the control module does not exceed the maximum operating chassis angle, the mechanical retraction switch is turned off, the tilt sensor stops measuring / updating the chassis angle, and the lower boom is released from its retracted position. The control module determines the maximum operating lower boom angle based on the received chassis angle. and b) The lower suspension boom angle is measured using a lower suspension boom sensor; the lower suspension boom angle is the angle of the lower suspension boom relative to the chassis surface. i. When the lower boom angle received by the control module is less than the maximum operating lower boom angle, the hydraulic enable valve is opened to activate the lower boom raising function, and ii. When the lower boom angle received by the control module reaches the maximum operating lower boom angle, close the hydraulic enable valve and disable the lower boom raising function.

11. The method according to claim 10, wherein, The maximum operating chassis angle is in the range of 7 to 10 degrees.

12. The method according to claim 10, wherein, The maximum operating chassis angle is 10 degrees.

13. The method according to claim 10, wherein, When the measured chassis angle is equal to or less than the predetermined tilt value, the maximum operating boom angle is 90 degrees.

14. The method according to claim 13, wherein, The predetermined tilt angle is 5 degrees.

15. The method according to claim 10, wherein, If the aerial elevator is equipped with a suitable stabilizer assembly, the maximum operating chassis angle can exceed 10 degrees.

16. The method of claim 10, wherein, The maximum operating lower boom angle is determined based on the measured chassis angle and additional parameters selected from the boom length, boom weight, overhead work platform load, and their combination.

17. The method according to claim 10, wherein, A set of sensors measures the chassis angle and the lower boom angle.

18. The method according to claim 10, wherein, Real-time measurement and monitoring of the lower boom angle.

19. An aerial elevator equipped with a tilt adjustment system according to any one of claims 1 to 9.

Images