System for hook speed control of a pipelayer

Abstract

A system for measuring the load from a cable associated with a lifting hook of a lifting system such as a pipe-laying machine is described. The system includes a load unit for detecting load data describing the load on the hook and a controller configured to control the maximum hook descent speed based on the load on the hook. The controller can determine the maximum speed by using sensor data (such as temperature data) and configuration data describing the composition of the machine and its components (such as the type of bearings, the configuration of blocks and pulleys, lubricants, and other such machine configurations) to select a speed curve from a predetermined set of speed curves. The controller enables the hook to descent up to the maximum speed based on the speed curve and can also be adjusted based on a gain setting to scale the maximum speed setting.

Description

Technical Field

[0001] This disclosure relates to a pipe-laying machine having booms for performing load lifting and lowering operations. More specifically, this disclosure relates to a system for monitoring and controlling the descent speed of a winch system. Background Technology

[0002] Pipe-laying machines are typically used to suspend and place loads, such as pipes, at installation sites. Pipe-laying machines generally include a boom for handling such loads. Additionally, pipe-laying machines include a boom lifting assembly for controlling the position of the boom during load installation. During installation, the pipe-laying machine may be subjected to forces based on the weight of the load borne by the boom and the load's position relative to the pipe-laying machine. Accurate measurement of these forces is desirable for efficient load installation. During installation, when the hook on the pipe-laying machine is lowered with no load or minimal load, such as when the load is lowered rapidly to prevent potential tipping of the pipe-laying machine, the winch drum may exceed the speed of the hook block. When the hook is lowered and touches the ground, and a lowering command is still given, the winch drum may continue to rotate, causing the winch cable to become tangled.

[0003] Chinese Patent No. 103523689 (hereinafter referred to as "'689 Patent") describes an oil drilling winch system and a control method for the system. '689 Patent describes a drilling winch system comprising a controller, an electromagnetic turbine brake, a disc brake, a drum shaft assembly, and a dual-gearbox. The dual-gearbox is connected to an AC variable frequency motor via a clutch and to the drum shaft assembly via a clutch. The drum shaft assembly is connected to the electromagnetic turbine brake via a spline, and the disc brake is splined between the drum shaft assembly and the electromagnetic turbine brake. The control system compares the speed of the winch hook with a set speed and uses an electromagnetic eddy current brake to control the winch hook within the set speed. This system provides a solution to the nesting problem in the oil industry by stopping the descent of the load in the drill string. This system provides rapid descent of the load over a long distance and then stops the load after reaching the target depth.

[0004] The '689 patent does not address the issue of load descent of the winch hook (e.g., to rapidly lower a load supported by the boom that could shift the center of gravity of the pipelaying machine to prevent it from tipping over). However, when the hook is lowered, when the hook on the pipelaying machine is lowered with no load or with minimal load, the winch drum may exceed the speed of the hook block, or when the winch is released, the drum may continue to rotate and cause bird's nesting of the winch cable when the hook contacts the ground. Summary of the Invention

[0005] In one aspect, this disclosure relates to a system for monitoring and controlling the load on a cable associated with a pipe-laying machine. The system includes: a load measuring component coupled between a boom block engaged with the cable and a portion of the pipe-laying machine, and configured to measure the load on the cable; a winch drum connected to the cable; a drive and braking system configured to control the rotation of the winch drum; and a controller configured to control the drive and braking system, wherein the controller is configured to receive load data from the load measuring component and, in response to the load data, control a maximum speed of the winch drum based on a speed curve.

[0006] In some examples, the technology of the system further includes a temperature sensor, wherein the controller is configured to control the drive and braking system based at least in part on temperature data from the temperature sensor. The controller may also be configured to control the drive and braking system based at least in part on system configuration settings describing the components of the pipe-laying machine. Controlling the drive and braking system may include selecting a speed curve from a plurality of speed curves based on the temperature data and the system configuration settings. The plurality of speed curves may describe a maximum speed as a function of a load measurement on the hook of the pipe-laying machine. The controller may include a gain setting configurable by user input, the gain setting being configured to reduce or set the maximum speed of the load on the speed curve based on the user input. The controller may also be configured to overshoot the maximum speed in response to user input.

[0007] In some aspects, the technology described herein relates to a pipe-laying machine comprising: a main frame; a boom configured to pivot relative to the main frame to allow the boom to be raised and lowered, the boom defining a first end coupled to the main frame and a second end remote from the main frame; a cable engaging with the second end of the boom and a hook, the cable being extendable via a winch coupled to the main frame; a load unit configured to measure the load on the cable; and a controller configured to control a maximum speed of the winch based on a load and speed profile determined, such as based on data from the load unit.

[0008] In some aspects, the technology described herein relates to a method for controlling a winch of a pipe-laying machine, comprising: receiving temperature data associated with the temperature of the winch of the pipe-laying machine at a controller of the pipe-laying machine; determining, by the controller and based on the temperature data, a speed curve describing the relationship between a load on the hook of the pipe-laying machine and a maximum winch speed; determining, by the controller and based on load data describing the load on the hook; determining the maximum speed of the winch based on the speed curve and the load data; receiving user input associated with a command for raising or lowering the hook; and controlling the winch based on the user input and the maximum speed of the winch. Attached Figure Description

[0009] Figure 1 It is a front view of an exemplary pipe-laying machine having a boom and cables associated with the boom, according to at least one example.

[0010] Figure 2 It is a system architecture of a pipe-laying machine winch system with adaptive winch speed control, based on at least one example.

[0011] Figure 3 It is based on at least one example of a lifting system and a winch with a load management controller configured to control the adaptive maximum hook speed of the lifting system.

[0012] Figure 4 It is a block diagram of the controller architecture of an enhancement system based on at least one example.

[0013] Figure 5 It is a block diagram of the control system of a machine based on at least one example. Detailed Implementation

[0014] refer to Figure 1 The diagram illustrates machine 100. In the illustrated embodiment, machine 100 is embodied as a pipe-laying machine for performing pipe-laying operations. Pipe-laying operations may include, but are not limited to, lifting and / or lowering loads, such as pipe segments, tube segments, culvert segments, drainage segments, etc., and installing loads at installation locations, such as trenches. In an exemplary pipe-laying operation, a pipe segment (to be installed in a trench) is lifted from the ground by machine 100, placed above the top of the trench, and lowered into the trench by machine 100.

[0015] During pipe-laying operations, the hook and winch mechanism of machine 100 are used to raise and lower the various sections of pipe. During such operations, in some cases, when the hook on machine 100 is lowered, the winch drum may exceed the speed of the hook block. When the hook is lowered and contacts the ground surface, and a lowering command is still given via user input, the winch cable may become brittle.

[0016] The description provided herein enables hook speed control to prevent winch birding-in during operation of machine 100. A machine load management indicator (LMI 158) system is used to limit the winch speed during a descent command to prevent the winch drum from exceeding the hook block speed, which depends on the hook load (e.g., the amount of load on the hook) and ambient temperature (among other configuration settings). LMI 158 is an adjustable machine software feature to accommodate different block masses / sizes and whether it has sleeve bearings, bushings, or ball bearings, and to accommodate different types and temperatures of lubricants used within the block. This feature can be enabled or disabled and can also be adjusted using gain settings to adjust the speed setting as a function of the load on the hook based on user input to the gain. Gain from the machine display allows the operator to adjust sensitivity to account for different empirical levels of lubricant viscosity used for lubrication blocks, grease / oil, and / or ambient temperature. Furthermore, if the winch is equipped with a rapid descent feature, an intelligent winch release feature can be overridden to enable rapid descent to prevent machine 100 from tipping over.

[0017] Although references to machine 100 have been used, aspects of this disclosure may also be applied to other working machines equipped with booms, lifting systems and winch systems for suspending loads, such as dragline excavators, rope excavators, cranes, etc., and references to machine 100 in this disclosure should be considered purely exemplary.

[0018] The machine 100 includes an operator's cab 102, a propulsion system 104, a main frame 106, a front end 108, and a traction device 110 for traveling on a ground surface 112. The traction device 110 includes a first track 114A and a second track 114B.

[0019] Machine 100 includes a boom assembly 130, a boom lifting assembly 128, and a counterweight assembly 116. A main frame 106 supports one or more components / assemblies of machine 100, such as the propulsion system 104, operator's cab 102, boom assembly 130, boom lifting assembly 128, and counterweight assembly 116; however, other known components and structures may also be supported by the main frame 106. The main frame 106 may define a front end 108 and a rear end (not shown) opposite the front end 108. The front end 108 and the rear end may be defined with respect to an exemplary direction of travel of machine 100, wherein the direction of travel is defined from the rear end toward the front end 108.

[0020] Furthermore, the main frame 106 may define two lateral sides, namely a first lateral side 132 and a second lateral side 118 opposite to the first lateral side 132. The two lateral sides (the first lateral side 132 and the second lateral side 118) may be laterally positioned relative to an exemplary direction of travel of the machine 100. Additionally, the main frame 106 may include a first track roller frame 136 and a second track roller frame 120. The first track roller frame 136 may be disposed at the first lateral side 132 of the machine 100, and the second track roller frame 120 may be disposed at the second lateral side 118 of the machine 100.

[0021] The traction device 110 can support the main frame 106 (and thus the machine 100) on the ground surface 112, and can be powered by the propulsion system 104 to facilitate the movement of the machine 100 over a wide area of ​​the installation site. The traction device 110 may include tracks or wheels, or a combination thereof. Figure 1 As shown, machine 100 includes two traction devices 110, namely a first track 114A and a second track 114B. The first track 114A can be coupled to a first track roller frame 136, and the second track 114B can be coupled to a second track roller frame 120. In other embodiments, it is conceivable that more or fewer tracks can be used in machine 100.

[0022] The propulsion system 104 may include a power compartment and a power source (not shown) disposed within the power compartment. The power source may include a gas turbine engine or an electric power source or a combination thereof. The power source may be configured to generate the output power required to operate various systems or components on the machine 100, one operation of which exemplarily involves pivoting the boom assembly 130 relative to the main frame 106 to raise or lower a load.

[0023] The operator's cab 102 can be supported on the main frame 106. The operator's cab 102 facilitates the placement of one or more operators to monitor and control the operation of the machine 100. Furthermore, the operator's cab 102 can house various components and controls of the machine 100, and access to one or more of these components and controls can assist the operator in performing pipe-laying operations. For example, the various components and controls of the machine 100 may include, but are not limited to, joysticks, switches, etc., to facilitate the operator's pipe-laying operations.

[0024] A boom assembly 130 may be disposed on a first lateral side 132 of the main frame 106. The boom assembly 130 is configured to lift and lower loads (e.g., pipe sections). The boom assembly 130 includes a boom, a first hook block 150, a second hook block 152, and a hook 154. The boom assembly 130 defines a first end 134 and a second end 146 opposite to the first end 134. The first end 134 of the boom assembly 130 is coupled to the main frame 106. For example, the first end 134 of the boom assembly 130 may be pivotally coupled to a first track roller carrier 136 using one or more hinge pins. The second end 146 of the boom assembly 130 is defined remotely from the main frame 106.

[0025] Furthermore, the boom assembly 130 may be formed from one or more leg segments. In this embodiment, as... Figure 1 As shown, the boom assembly 130 may include two or more leg segments. These leg segments extend between a first end 134 and a second end 146 of the boom assembly 130. For example, two leg segments may be pivotally coupled to a first track roller frame 136 at the first end 134 of the boom assembly 130 (via a hinge pin) and coupled to each other at the second end 146 of the boom assembly 130. In this illustrated configuration, these leg segments give the boom assembly 130 a substantially elongated and triangular structure. In other embodiments, the boom assembly 130 may include a single or multiple leg segments depending on application requirements.

[0026] The boom assembly 130 is configured to pivot relative to the main frame 106. The boom assembly 130 can be in a raised position relative to the main frame 106 (e.g., Figure 1 The boom assembly 130 is pivotable between a raised position (shown in the diagram) and a lowered position (shown in dashed lines). In the example, the raised position of the boom assembly 130 can be a generally vertical or retracted position that facilitates the machine 100's movement across the site, while the lowered position of the boom assembly 130 can be a generally horizontal position that facilitates extension to suspend the load over the ditch.

[0027] A first hook block 150 can be pivotally connected to a second end 146 of a boom assembly 130. A second hook block 152 can be operatively connected to the first hook block 150 using a cable 148. The cable 148 can be actuated using a hook winch 122 supported on the main frame 106. Furthermore, a hook 154 can be connected to the second hook block 152. The hook 154 can be configured to suspend a load to be lifted (or lowered), such as a pipe section. During pipe-laying operations, the cable 148 can be actuated by the hook winch 122 to raise or lower the second hook block 152 and the hook 154 relative to the ground surface 112.

[0028] The boom lifting assembly 128 is now discussed. The boom lifting assembly 128 can be operated in a manner that allows the boom assembly 130 to move (e.g., pivot) relative to the main frame 106. For example, the boom lifting assembly 128 facilitates the pivoting of the boom assembly 130 relative to the main frame 106 between a raised position and a lowered position. The boom lifting assembly 128 includes a boom winch 124, a first boom block 142, a second boom block 140, and a boom cable 138.

[0029] The boom winch 124 may include a frame 126 and a drum at least partially disposed within the frame 126. The frame 126 may be disposed toward a second lateral side 118 of the main frame 106. The frame 126 may define a pair of coaxial mounting holes. The drum may be configured to operate in a manner that actuates the boom cable 138. For example, the drum may be powered (e.g., via a power source) to rotate in one direction to wind the boom cable 138 around it and to rotate in the opposite direction to unwind the boom cable 138 from it. The winding or unwinding of the boom cable 138 around the drum may cause the boom assembly 130 to pivot relative to the main frame 106 between a raised position and a lowered position.

[0030] The first boom block 142 may include a housing and one or more first pulleys coupled to the housing. The first pulleys may be configured to receive and guide the boom cable 138 between the boom winch 124 and the second boom block 140. The first boom block 142 is coupled to a second end 146 of the boom assembly 130. For example, the housing of the first boom block 142 defines a first mounting portion to facilitate a pivotal connection between the first boom block 142 and the second end 146 of the boom assembly 130.

[0031] The second boom block 140 can be supported on the main frame 106. The second boom block 140 may include a housing and a pair of second pulleys connected to the housing. The second pulleys can receive boom cables 138 from the first boom block 142 and guide boom cables 138 back to the first boom block 142 (or boom winch 124) to operatively connect the second boom block 140 to the first boom block 142 and the boom winch 124.

[0032] In the illustrated configuration, the boom cable 138 can extend back and forth four times between the first pulley of the first boom block 142 and the second pulley of the second boom block 140. However, it should be noted that the boom cable 138 can extend fewer or more times depending on the number of first and second pulleys. This engagement between the boom winch 124, the first boom block 142, and the second boom block 140 (formed via the boom cable 138 extending therebetween) helps the boom winch 124 to pivot the boom assembly 130 relative to the main frame 106.

[0033] During pipe-laying operations, the boom assembly 130 may be subjected to various forces (or moments), for example, due to the weight and position of the load suspended from the hook 154. If left unchecked, such forces (or moments) could affect the stability of the machine 100, and in the worst case, could cause the machine 100 to tip over. Therefore, it is necessary to determine such forces (or moments) to avoid dangerous tipping situations and thus enhance the stability of the machine 100. To determine the forces (or moments) exerted on the boom assembly 130 due to the suspended load, the load (e.g., tension) from the boom cable 138 is measured. Figure 1 In the example shown, the load can be determined using a load unit 144 connected between the first boom block 142 and the second end of the boom assembly 130. The load value determined based on data from the load unit can be used to determine the weight on the hook 154.

[0034] The LMI 158 can receive load data from the load unit 144, and also receives sensor data and configuration data from the machine. This document discusses... Figure 3-5 The winch speed controller 160, described in further detail, provides control over the winch's clutch and braking system, particularly the winch drum, and provides control over the rotational speed of the winch drum based at least in part on load data from the load unit 144 and additional data including configuration data and other sensor data.

[0035] The winch speed controller 160 is configured to control the drive, clutch, and braking systems of the winch drum, wherein the controller is configured to receive load data from a load measurement unit and control the maximum speed of the winch drum in response to the load data based on a speed curve. The winch speed controller 160 can receive configuration data, such as the number of cable legs, the number of pulleys, the type of bearings or bushings, the type of grease, and other such machine configuration data, via a user interface 162. The winch speed controller 160 can also receive sensor data associated with the load unit 144, temperature data from temperature sensors (e.g., ambient temperature and / or the temperature of the grease, winch, or pulleys of the hoisting system). The winch speed controller 160 can determine the speed curve by selecting a predetermined speed curve related to the maximum speed of the winch drum and / or the hook speed as a function of load measurements on the hook. The speed curve can be pre-generated based on load and speed data associated with the winch or hoisting system and information on whether speed conditions can be associated with conditions beneficial to nesting. Multiple speed curves associated with different temperatures, machine configurations, and other settings can be generated. Therefore, the winch speed controller 160 can determine one or more settings and select an appropriate speed curve based on these settings.

[0036] The controller may include a gain setting configurable by user input via user interface 162, which is configured to reduce or adjust the maximum speed of the speed curve based on user input, for example, setting a lower maximum speed for a specific load. The winch speed controller 160 may also be configured to overshoot the maximum speed in response to user input, for example, to prevent instability of machine 100.

[0037] The counterweight assembly 116 pivots to resist movement of the boom assembly 130, thereby maintaining machine stability during boom extension (as shown by the dashed line). In the event of boom extension (e.g., along direction 156), if the load on the hook 154 causes instability in the machine 100, the operator can select user input, such as a button or plunger, to quickly release the hook to lower it under gravity with the brake and clutch assemblies disabled.

[0038] Figure 2 The system architecture is based on at least one example of a lifting system 200, which includes a winch system 202 for a pipe-laying machine with adaptive winch speed control. The pipe-laying machine may be... Figure 1 Example of machine 100. The winch system 202 includes at least a clutch 204 and a brake 206 for controlling the rotation of the winch drum. The winch system 202 is controlled by a controller 230, which can set the maximum rotational speed of the winch drum during hook descent to prevent cable nesting during hook descent, particularly when the hook is loaded with a load below a threshold amount.

[0039] Controller 230 can provide a dynamic maximum speed setting for winch system 202 based on a speed curve, as described above and as per [reference to...] Figure 3 As shown and described. Controller 230 can receive inputs of sensor data 208 and configuration data 222, as well as controller implementation, via activation signal 232. Therefore, controller 230 can select a customizable and / or configurable speed curve for implementation based on the current conditions in the environment of machine 100 and the settings of machine 100.

[0040] Sensor data 208 includes data relating to boom distance 210, ambient temperature 212, winch spool speed 214, load sensor 216, grease type / temperature 218, and command speed 220. Boom distance 210 may include data describing the angle and / or position of boom assembly 130, such as data from a position sensor at the hinge connecting boom assembly 130 to main frame 106. Boom distance 210 may include information relating to the horizontal position of the end of boom assembly 130. Ambient temperature 212 may include information relating to the temperature of the environment surrounding machine 100. Ambient temperature 212 may include temperature data varying over time, such as temperature trend information. Winch spool speed 214 may include speed data describing the rotational speed of the winch drum, such as data from a rotary encoder or other such sensor configured to measure the rotational speed of the drum. Load sensor 216 may include load unit 144 of machine 100 or other such sensor configured to detect load on hook 154. Grease type / temperature 218 may include an indication of the type of grease or lubricant used within the lifting system 200, such as the grease type, and also includes the temperature of the lubricant (e.g., grease). Temperature may include temperature data over time, temperature trends (e.g., increasing or decreasing over time), and other such information. Command speed 220 may include data related to input received from the operator, including the speed at which the hook 154 is commanded to change its height. Command speed 220 may also include information related to the direction of the command to the hook 154, such as information against gravity or in the direction of gravity.

[0041] Configuration data 222 may include data describing the configuration of machine 100, which may not be associated with sensor data but may be input or provided through a user interface or other input device. Configuration data 222 includes block configuration 224, block size 226, bearing type 228, and other such information. Block configuration 224 may include information relating to the configuration of the first, second, or other blocks of machine 100, such as the shape and dimensions of the blocks, the number of pulleys, and other such information. Block size 226 may include information relating to the number of cable sections (e.g., the number of cable lengths between pulleys and / or the number of pulleys). Bearing type 228 may describe the type of bearings and / or lubrication included within the lifting system, such as bearings, bushings, grease, or other such lubricants.

[0042] The controller 230 can use sensor data 208 and configuration data 222 to select the speed profile for controlling the winch system 202. (See also: ...) Figure 3The speed curve is selected and / or scaled as described. Controller 230 can be enabled, and based on configuration data 222 and current data from sensor data, the speed curve can be selected to provide a maximum speed for the hook according to the load on the hook. Controller 230 can also receive input from the user and determine a gain setting 234 that can be related to the sensitivity of controller 230. Gain setting 234 can be used to adjust the maximum speed of the hook controlled by controller 230. The gain setting can be manipulated based on user input to adjust the maximum speed of the speed curve as a function of the load on the hook; for example, for a specific load on the hook, increasing the gain setting can increase the maximum speed, and decreasing the gain setting can decrease the maximum speed.

[0043] The winch system 202 may have a control system 236, which can be activated to lower the hook 154 to the ground surface 112 via a control controller 230, clutch 204, and brake 206, regardless of the maximum speed indicated by the speed curve. The control system 236 can be used to prevent instability of the machine 100 if the boom assembly 130 extends from the side of the machine 100 and tipping can begin based on the boom position and load on the hook 154. In this example, boom distance 210 and load data from load sensor 216 can be used to assess potential instability of the machine 100 and activate the control system. In this example, the machine 100 may automatically engage the control system 236 in response to boom distance 210 and load sensor 216 and / or other data related to the rotational position of the machine 100 relative to the ground surface 112 and / or gravity.

[0044] Figure 3 This refers to a lifting system 300 according to at least one example and a winch having a load management controller 316, the load management controller being configured to control the adaptive maximum hook speed of the lifting system 300. The lifting system 300 in... Figure 3The diagram is simplified to represent a potential lifting system for a pipe-laying machine, crane, or other such machine using cable 306 and winch 302, the winch including a winch drum for winding the cable to raise and lower hook 312. As shown, lifting system 300 includes a block 308 having the length of cable 310, for providing the mechanical advantage of lifting items using hook 312 by including the length of the cable between the cables disposed in block 308. Lifting system 300 operates by rotating winch 302 in direction 304 to wind or unwind cable 306, and thus raise or lower hook 312 along direction 314. During lowering operations (e.g., in a direction parallel to the same direction as gravity), if hook 312 is lowered at too fast a rate, winch 302 may exceed its limits and cause cable 306 to become brittle when winch 302 rotates excessively, for example when hook 312 reaches the ground surface, causing cable 306 to slack. To prevent this nesting, the load management controller 316 is implemented to set a dynamic maximum speed for lowering the hook 312. In some examples, the maximum speed can be used to raise and lower the hook 312.

[0045] The load management controller 316 receives data such as speed data 318, which describes the speed of the cable 306 being released. Speed ​​data 318 can be determined from sensors on the cable guide and / or based on the rotational rate of the winch drum or some other speed data. Speed ​​data 318 may also include a speed requested as a result of operator input, such as a speed requested by pressing a joystick or other user interface element. The load management controller 316 also receives temperature data 320 and load data 322. Temperature data 320 may be associated with the temperature of one or more components of the lifting system 300, such as the winch 302, block 308, or other such components. Temperature data 320 may also include ambient temperature data of the environment surrounding the lifting system 300. Load data 322 may include load data associated with a load disposed on the hook 312 and may be detected by a load unit connected to one of the blocks 308 or another component of the lifting system 300, the load unit being configured to isolate and determine the load on the hook 312.

[0046] The load management controller 316 uses a speed curve 326 that can be selected based on operating criteria, including the configuration of the lifting system 300, such as the specific arrangement of components, the type of components, and information such as ambient temperature and / or the temperature of the lifting system 300. The speed curve 326 can also be adjusted or reduced using gain 324 to determine the dynamic maximum speed of the hook 312, especially during descent. The speed curve 326 depicts functions 332, 334, and 336, which represent different maximum speeds 330 as a function of the load 328 on the hook 312. Functions 332, 334, and 336 are depicted as having similar shapes, but may differ in some examples. The speed curve 326 includes multiple functions based on different temperatures and system configurations of the lifting system 300 (although only three are depicted, additional functions are conceivable). A combination of the lifting system configuration and temperature data 320 can be used to select a function of the speed curve 326, which the load management controller 316 uses to set the maximum hook travel speed as a function of the load data 322. This configuration may include information such as cable diameter, cable material, number of pulleys, block configuration, hook weight, cable length, type of bushings or bearings in the blocks, type of lubricant in the blocks, and other configuration parameters of the lifting system 300. By providing the load management controller with the specific lifting system configuration settings, the load management controller can select from a predetermined speed curve.

[0047] The trend 338 between functions typically specifies that, when controlling the load, a function with a higher plot on the speed curve allows for a higher maximum descent speed of the hook 312 than a function with a lower plot. For example, vertical movement along trend 338 can allow for compensation for temperature differences or variations. In the illustrative example, function 336 can be used when the temperature associated with the lifting system 300 is lower than the temperature associated with the lifting system when function 334 is selected. The lower maximum speed may take into account variations in the viscosity of the grease in block 308 or other such variations in temperature that may contribute to the nesting of the winch cable.

[0048] Gain 324 can be used to adjust or reduce the maximum speed of the hook at a load value and can be a user-configurable setting. As shown, speed curve 342 illustrates the adjustment of a specific speed function 344 based on the gain 324 setting input by the operator. Function 344 represents different maximum speeds as a function of the load on the hook 312. As shown, function 344 provides a first maximum speed 346 at a load value 352 associated with neutral or zero gain adjustment, meaning that function 344 indicates the maximum speed without any adjustment. Gain 324 can be used, for example, to reduce and / or adjust the maximum speed using positive gain adjustment associated with a second maximum speed 348 for the load value 352 and negative gain adjustment associated with a third maximum speed 350 for the load value 352. For example, an experienced operator can use gain 324 to adjust the maximum speed for a load value, allowing the experienced operator to move the hook at a higher travel speed. Less experienced operators can use gain 324 to reduce or decrease the maximum speed and reduce the maximum hook speed. In some examples, gain 324 may be expressed as a percentage, such as adjusting the maximum speed indicated by the function by a percentage indicated by gain 324. In some examples, gain 324 may be expressed as a unitless value, used to reduce or increase the maximum speed by an absolute amount at any load value. Although a speed curve 342 is depicted with respect to a specific load value 352, the maximum speed setting will adjust vertically as the load value changes. As the load value increases, the first maximum speed 346 will shift upward following function 344. The second maximum speed 348 and the third maximum speed 350 shift similarly with the first maximum speed 346 when the load value changes. The same adjustment occurs when the load value decreases and the first maximum speed 346 decreases.

[0049] Functions 332, 334, and 336 can be generated through empirical testing, for example, testing the hook speed relative to the load as the hook 312 lowers and contacts the ground to identify thresholds for different load amounts that are unlikely to cause nesting, or thresholds that will not cause nesting. In the example, functions 332, 334, and 336 can also be generated using one or more machine learning methods. For example, after collecting data for a specific configuration of the lifting system 300 as described above, a trained machine learning algorithm can output functions for additional configurations of the lifting system beyond those generated by empirical testing.

[0050] Figure 4This is a block diagram of the architecture of a controller 402 of a lifting system 400 according to at least one example. The lifting system 400 operates to wind in and out cables, such as boom cables 138 or cables 148. The lifting system 400 is powered by a power source such as an engine 404, which may include an internal combustion engine or any other suitable power source. In an embodiment, the lifting system 400 may include a generator 406 operatively connected to the engine 404 via a drive shaft, transmission, belt, chain, pump, or any suitable power transmission mechanism. The generator 406 converts power from the engine 404 (such as torque as the power source rotates during operation) into electrical electricity (such as AC current). An inverter 408 is electrically connected to the generator 406, and a drive motor 410 is electrically connected to the inverter 408. The drive motor 410 is configured to propel the machine 100 via one or more sprockets 412 (which may engage with a ground engagement structure such as a wheel or annular tread). The inverter 408 is configured to convert AC power from the generator 406 into DC power.

[0051] The lifting system 400 may include a winch motor 416 electrically connected to an inverter 408. The winch motor 416 can have any desired configuration. In one embodiment, the winch motor 416 may be a switched reluctance motor operating using AC power. In operation, DC power may be supplied by the inverter 408 via a cable or cable assembly to a second or half-inverter 414 that converts DC power to AC power. AC power is then supplied via the cable assembly to drive the winch motor 416. In other embodiments, the inverter 408 may be configured to supply AC power to the winch motor 416 without the half-inverter 414. In still other embodiments, the winch motor 416 may be a DC motor, and DC power may be supplied by the inverter 408 or, without the half-inverter 414, by another source on the machine. In still other embodiments, the winch motor 416 may be hydraulic or electro-hydraulic. Although an electrical system is given as an example of a device disclosed herein for operating a winch, it should be understood that hydraulically actuated winches are more typically used in pipe-laying machines and other machines designed for use in construction and other environments.

[0052] The winch drum 424 of the winch can be operatively connected to the winch motor 416 via a gear system 420 operatively connected to the motor. In an embodiment, the gear system 420 can be configured to provide multiple rotations of the winch motor 416 for each rotation of the winch drum 424. Rotation of the winch drum 424 can be stopped or prevented by a braking system 422 operatively connected thereto. The gear system 420 and the braking system 422 can have any desired configuration. In an embodiment, the gear system 420 and the braking system 422 can be configured with a default state in which rotation of the winch drum 424 is prevented (e.g., thereby applying a brake) unless the braking system is disengaged. The winch drum 424 can be configured with cable wound around it multiple times. The number of times the cable is wound around the winch drum 424 is a function of the drum size and the length and diameter of the cable. Other configurations of the lifting system 400 are contemplated.

[0053] The operation of engine 404, lifting system 400, and other systems and components of machine 100 is controlled by controller 402, such as Figure 4 As shown in the general outline. Figure 5 A schematic example of a controller or control system is shown. For example, controller 402 can receive input signals from an operator operating machine 100 from inside the cab or from outside the machine via a wireless communication system.

[0054] Controller 402 can be any electronic controller configured to operate logically to perform operations, execute control algorithms, store and retrieve data, and perform other desired operations. Controller 402 may include or have access to memory, auxiliary storage devices, a processor, and any other components for running at least one application. Memory and auxiliary storage devices may take the form of read-only memory (ROM) or random access memory (RAM) or integrated circuits accessible to the controller. Various other circuits may be associated with controller 402, such as power supply circuits, signal conditioning circuits, driver circuits, and other types of circuits.

[0055] Controller 402 may be a single controller, or may include more than one controller configured to control various functions and / or features of machine 100. The term "controller" is intended to be used in its broadest sense to include one or more controllers and / or microprocessors that can be associated with machine 10 and can cooperate in controlling various functions and operations of the machine. The functionality of controller 402 may be implemented in hardware and / or software, regardless of the specific functions. Controller 402 may rely on one or more data graphs relating to the operating conditions and operating environment of the machine that can be stored in the controller's memory. Each of these data graphs may include a set of data in tabular, graphical, and / or equation form.

[0056] The controller 402 may be physically located on machine 100 and may also include components located remotely from the machine. The functionality of the controller 402 may be distributed, such that some functions are performed at machine 100 while others are performed remotely.

[0057] Figure 5 This is a block diagram of a control system 500 for at least one example machine. The control system 500 also includes a control unit 502 with an input / output interface 514 for receiving inputs from various sensors and sending outputs of the nature of control commands, monitored quantities or qualities, and condition alarms, as further discussed herein. The control unit 502 also includes a processor 516, which may include any suitable central processing unit, such as a microcontroller or microprocessor. The processor 516 communicates with a memory 518 storing computer-executable program instructions of the nature of a load monitoring program 520 or control routine and a cable feed program 522 or control routine, as further discussed herein. The memory 518 may include RAM, ROM, a hard disk drive, flash memory, SDRAM, EEPROM, or another type of memory. A speed curve 524 is referenced by the load monitoring program 520 to determine the load condition of the machine 100, such as the maximum hook speed for lowering the hook relative to the load on the hook of the machine 100. The display 526, which can be installed in or on an operator station, may include a graphical user interface, such as a touchscreen (unnumbered), configured to transmit various types of information to and receive control input from the operator. For example, multiple icons may represent alarms or warnings that can be presented to the operator by illumination. Other operator-perceptible alarms, such as audible alarms, may be used.

[0058] Load monitoring program 520 may receive load data from one or more load units of machine 100 to determine the load on the hook of the machine. Cable feeding program 522 may receive data from cable feeding sensor 512 to determine the amount of cable released and / or the rate of cable feeding. Speed ​​profile 524 may include multiple speed profiles describing the maximum speed at which control unit 502 controls the winch, brake, and / or clutch based on the load detected on the hook of machine 100. In this way, control unit 502 may control the maximum speed to a lower maximum speed in response to the load on the hook being below a threshold and / or describe the mathematical relationship between the maximum speed and the load on the hook. Speed ​​profile 524 may include multiple different speed profiles based on different configuration settings of the machine and / or other data such as temperature data, as described herein. Therefore, control system 500 may control the winch, clutch, and / or brake to prevent cable release when the hook is descending at a rate higher than the maximum speed determined by the relationship on a particular speed profile.

[0059] A main sensor 504 generates a main monitoring signal for the frame of machine 100, indicating the orientation of the main frame relative to an underlying substrate. A cable guide sensor 506 is configured to generate a cable guide monitoring signal indicating the orientation of the boom and associated cable guide. The control system 500 also includes a load sensor 510 configured to generate a load monitoring signal indicating the load on the lifting cable and / or hook. In one embodiment, each of the cable guide sensor 506 and the load sensor 510 resides on the boom assembly 130. The control system 500 also includes a cable feed sensor 512 configured to generate a cable feed signal indicating the length of the lifting cable fed through the cable guide and / or released from the winch drum. The cable feed sensor 512 may also reside on the cable guide and / or the winch drum. A counterweight sensor 508 is associated with the machine's counterweight and configured to generate a counterweight monitoring signal indicating the orientation of the counterweight relative to the frame of machine 100. It should be understood that the position of any pivotable component of interest discussed herein can indicate orientation, and vice versa, making the terms position and orientation interchangeable. Therefore, the relative position and orientation of the components of machine 100 can be indicated directly, indirectly, or inferred using rotary potentiometers, linear potentiometers, Hall effect sensors, inductive sensors, capacitive sensors, mechanical switches, etc., the importance of which will become further apparent from the following description.

[0060] Industrial applicability During pipe-laying operations, the hook can be lowered to bring the pipe, load, or hook itself down to contact the ground surface. Upon contact with the ground, momentum within the winch drum can cause it to continue rotating, potentially creating slack in the cable supporting the hook. This slack and continued rotation of the winch drum can lead to cable entanglement or birding-in-the-hole formation. Such entanglement can render the pipe-laying machine inoperable until the cable is untangled, straightened, and possibly replaced. Therefore, preventing birding-in-the-hole formation on the winch of the pipe-laying machine or other lifting systems prevents significant machine downtime and maintenance costs.

[0061] In this regard, the present disclosure provides a load management controller capable of receiving load data describing the load on the hook of a lifting system, and using a pre-generated speed curve to set the maximum hook travel speed while reducing the hook to prevent or reduce nesting.

[0062] Pipe-laying operations may include, but are not limited to, lifting and / or lowering loads, such as pipe segments, tube segments, culvert segments, drainage segments, etc., and installing loads at installation locations, such as trenches. In an exemplary pipe-laying operation, a pipe segment (to be installed in a trench) is lifted from the ground by machine 100, placed above the top of the trench, and lowered into the trench by machine 100.

[0063] During pipe-laying operations, the hook and winch mechanism of machine 100 are used to raise and lower pipe sections to positions on the ground and / or within trenches (e.g., on the bottom surface of the trench). During such operations, in some cases, when the hook on machine 100 is lowered and contacts the ground surface, the winch drum may exceed the speed of the hook block. When the hook is lowered and contacts the ground surface, and a lowering command is still given via user input, the winch cable may become brittle.

[0064] The description provided herein enables hook speed control to prevent winch birding-in during operation of machine 100. A machine load management indicator (LMI 158) system is used to limit the winch speed during descent commands to prevent the winch drum from exceeding the hook block speed, which depends on the hook load (e.g., the amount of load on the hook) and ambient temperature (among other configuration settings). LMI 158 is an adjustable machine software feature to accommodate different block masses / sizes and whether it has sleeve bearings, bushings, or ball bearings, and to accommodate different types and temperatures of lubricants used within the block. This feature can be enabled or disabled and can also be adjusted based on user input using adjustable gain settings. Gain from the machine display allows the operator to adjust sensitivity to account for different empirical levels of lubricant viscosity, grease / oil, and / or ambient temperature that affect the lubricant viscosity used for the lubricated block. Furthermore, if the winch is equipped with a rapid descent feature, an intelligent winch release feature can be overridden to enable rapid descent to prevent machine 100 from tipping over.

[0065] Unless explicitly excluded, the singular is used to describe a component, structure, or operation and does not preclude the use of a plurality of such components, structures, or operations or their equivalents. In the context of describing the invention (particularly in the context of the following claims), the terms “a” and “an” and “the” and “at least one” or the terms “one or more” and similar references should be interpreted to encompass both the singular and plural, unless otherwise stated herein or explicitly contradicted by the context. The use of the term “at least one” followed by a list of one or more items (e.g., “at least one of A and B” or one or more of A and B) should be interpreted to indicate a selection of one item (A or B) from the listed items or any combination of two or more of the listed items (A and B; A, A and B; A, B and B), unless otherwise stated herein or explicitly contradicted by the context. Similarly, as used herein, the word “or” refers to any possible permutation of a set of items. For example, the phrase “A, B or C” means at least one of A, B, C or any combination thereof, such as any of the following: A; B; C; A and B; A and C; B and C; A, B and C; or multiple items such as A and A; B, B and C; A, A, B, C and C, etc.

[0066] It will be apparent to those skilled in the art that various modifications and alterations can be made to the systems / pipe-laying machines disclosed herein without departing from the scope of this disclosure. Other embodiments will be apparent to those skilled in the art in light of the description and practice of the systems and / or pipe-laying machines disclosed herein. The specification and examples should be considered exemplary only, and the true scope of this disclosure is indicated by the following claims and their equivalents.

Claims

1. A system for monitoring and controlling the load on a cable associated with a pipe-laying machine, the system comprising: A load measuring component is coupled between a hanger block engaged with the cable and a portion of the pipe-laying machine, and is configured to measure the load on the cable; A winch drum connected to the cable; A drive and braking system configured to control the rotation of the winch drum; as well as A controller configured to control the drive and braking system, wherein the controller is configured to receive load data from the load measurement component and control the maximum speed of the winch drum in response to the load data based on a speed curve.

2. The system of claim 1, further comprising a temperature sensor, wherein the controller is configured to control the drive and braking system based at least in part on temperature data from the temperature sensor.

3. The system of claim 2, wherein the controller is further configured to control the drive and braking system based at least in part on system configuration settings that identify components of the pipelaying machine.

4. The system of claim 3, wherein the controller is configured to control the drive and braking system by selecting the speed curve from a plurality of speed curves based on the temperature data and the system configuration settings.

5. The system of claim 4, wherein the plurality of speed curves indicate the maximum speed as a function of the load on the hook of the pipe-laying machine.

6. The system of claim 1, wherein the controller includes a gain setting configurable by user input, the gain setting being configured to adjust a maximum speed based on the user input.

7. The system of claim 1, wherein the controller is further configured to exceed the maximum speed in response to user input.

8. A pipe-laying machine, comprising: Main framework; A boom configured to pivot relative to the main frame to allow the boom to be raised and lowered, the boom defining a first end connected to the main frame and a second end remote from the main frame; A cable that engages with the second end of the boom and the hook, the cable being extendable via a winch connected to the main frame; A load cell configured to measure the load on the cable; as well as A controller configured to control the maximum speed of the winch based on a load and speed curve determined from data from the load unit.

9. The pipe-laying machine of claim 8, further comprising a temperature sensor, wherein the controller is configured to control the winch based at least in part on temperature data from the temperature sensor.

10. The pipe-laying machine of claim 9, wherein the controller is configured to control the winch by selecting the speed curve from a plurality of speed curves based on the temperature data and system configuration settings.

11. The pipe-laying machine of claim 8, wherein the controller is further configured to exceed the maximum speed in response to user input.

12. A method for controlling the winch of a pipe-laying machine, comprising: Temperature data associated with the temperature of the winch of the pipe-laying machine is received at the controller of the pipe-laying machine; The controller determines a speed curve describing the relationship between the load on the hook of the pipe-laying machine and the maximum winch speed based on the temperature data; The controller determines load data related to the load on the hook based on data from the load sensor system; The maximum speed of the winch is determined based on the speed curve and the load data. Receive user input associated with commands for raising or lowering the hook; as well as The winch is controlled based on the user input and the maximum speed of the winch.

13. The method of claim 12, further comprising determining a gain input of the controller, the gain input being configured to adjust the speed curve to regulate the maximum speed.

14. The method of claim 12, further comprising determining one or more system configurations of the winch and lifting system of the pipelaying machine, wherein the speed profile is further determined based on the one or more system configurations.

15. The method of claim 12, further comprising: Determine the ground contact of the load on the hook; as well as When the load decreases, the winch drum is controlled in response to the decrease in load on the hook to reduce the maximum speed of the winch and prevent the winch cable from tangling.

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