Remote radio control system for cranes and other mobile equipment

Abstract

A platform for improved radio control systems for mobile equipment (e.g., cranes) is provided with different types of transmitters (base transmitter, standard transmitter, belly box transmitter, and mill belly box transmitter) and different types of receivers (standard crane mounted receiver, digital receiver, scalable receiver operable with different internal expansion cards and different external receiver boards) from which a user can create a custom radio system for their desired radio controlled machine application (e.g., a DC radio system or an AC radio system for industrial and commercial environments). The transmitters have platform universal battery packs and charger compatibility. The transmitters / receivers have a USB connection for data logging, as well as various indicators (e.g., three color LEDs) for battery status, pairing status, and / or operational configuration or status (e.g., fault). The transmitters / receivers are supplied with a base configuration or a customer specific configuration; and a button interface, or a configuration software application and interface for modifying the configuration.

Description

Technical Field

[0001] This disclosure generally relates to a system for controlling a mobile piece of equipment, machine, or device (e.g., a crane). More specifically, this disclosure generally relates to a remote radio control system that allows an operator to communicate using a battery-powered wireless transmitter with a powered receiver connected to or otherwise installed on a radio-controlled machine (RCM) device (e.g., a crane or other mobile equipment) to operate the RCM device (e.g., control the movement of the RCM device). Background Technology

[0002] A crane is a type of device used to lift and lower materials and move them horizontally. It is primarily used to lift heavy objects and transport them to other locations. The device uses one or more simple machines to generate mechanical advantage and thus move loads beyond normal human capabilities. Cranes are commonly used in the transportation industry for loading and unloading goods, in the construction industry for moving materials, and in the manufacturing industry for assembling heavy equipment.

[0003] Before the advent of radio-controlled systems, cranes were operated using one of two types of controls: cable-mounted cab controls or wired overhead controls. The biggest problem with cab controls was that most applications required more than one person. Crane operators often needed ground assistance to lift and position loads, and many operations required observers or relay personnel to guide the operator visually or verbally.

[0004] Wired overhead control systems address these issues by placing the operator on the ground near the load. The operator can hoist and position the load, and the possibility of direct line of sight eliminates the need for an observer. However, wired overhead control systems also have some drawbacks. They require the operator to walk along the ground following the crane's path, which can increase the risk of tripping or falling injuries, and can slow down operations if the crane moves faster than the operator can safely walk. Wired overhead control systems also require the operator to always be close to the load. This proximity can be particularly dangerous when handling heavy or hazardous loads, increasing the risk of operator injury. The operator must avoid the load and be careful not to get tangled in the cables, which is both unsafe and time-consuming.

[0005] Wireless remote radio controls solve the problems of cab-mounted and wired suspension controls, offering the benefits of both. Operators can perform lifting and guiding tasks from the ground, thus requiring fewer workers to be drawn from other positions. Operators also have better visibility, as he or she can potentially move to a location on the ground that provides the best view of the crane operation, potentially eliminating the need for additional observers or relay personnel.

[0006] However, wireless remote control devices for cranes have several drawbacks. For example, the radio receivers are often too simple, offering only two speed settings for controlling electric functions, and are not easily configurable for different types of cranes or other remote control equipment or different applications. For instance, some manufacturers of industrial radio transmitters and receivers incorporate unique features into their radio control product lines, but their product lines are otherwise uncustomizable, failing to allow users to tailor commercially available radio control transmitters and / or receivers to their specific applications. Summary of the Invention

[0007] The illustrative embodiments overcome the above and other problems and achieve additional advantages.

[0008] This illustrative embodiment provides a kit including at least one transmitter and at least one receiver configured to pair for wireless communication with each other to control the operation of one or more radio-controlled machine (RCM) devices. Each of the at least one receiver has an electrical output connected to a corresponding electric control element in the radio-controlled machine. Each of the at least one transmitter has a configurable user input interface, wherein the transmitter is operable to generate a command signal for operating one or more of the electric control elements in response to user manipulation of a corresponding element in the user input interface, and transmits the command signal to the receiver, and the receiver is operable to provide an output signal to the corresponding one or more of the electric control elements to cause them to operate according to the command signal.

[0009] According to an aspect of the illustrative embodiment, the kit further includes an RCM configuration generator application for creating a profile for at least one of the at least one transmitters, the profile describing a mapping of the user input interface corresponding to the transmitter's movement speed / direction selection to the output signal of the at least one receiver.

[0010] According to an aspect of the illustrative embodiment, the kit further includes an RCM interface application configured for user access, manipulation, and visualization of details of at least one of the one or more RCM devices.

[0011] According to an aspect of the illustrative embodiment, the RCM interface application is a Windows operating system application.

[0012] According to an aspect of the illustrative embodiment, a user can connect at least one of the one or more RCM devices to a Windows-based computer via a USB connection and manipulate and interact with the RCM device to perform one or more tasks selected from transmitting configuration settings, retrieving operation logs, and initiating equipment diagnostics.

[0013] According to an aspect of the illustrative embodiment, the RCM interface application is configured to process the configuration file and transmit the configuration settings therefrom to the transmitter.

[0014] According to an aspect of the illustrative embodiment, the kit further includes a DIP switch disposed on the at least one transmitter and the at least one receiver and configured to allow a user to form a DIP switch setting for the corresponding one of the at least one transmitter and the at least one receiver.

[0015] According to an aspect of the illustrative embodiment, the kit further includes a battery compartment disposed in the at least one transmitter and configured to accommodate one or more removable batteries, wherein the DIP switch is accessible in the battery compartment.

[0016] According to an aspect of the illustrative embodiment, the DIP switch disposed on the at least one transmitter is configured to assign functions to a configurable user input interface on the transmitter, the functions being selected from motion functions and auxiliary functions, wherein the auxiliary functions are selected from A / B transmitter functionality, single relay contact enable function and instant / switching on / off, inactivity time selection.

[0017] According to an aspect of the illustrative embodiment, the DIP switch disposed on the at least one receiver is configured with a DIP switch setting array that allows a user to configure unique settings for the receiver for features selected from: DIP switch control or RCM configuration selection, relay output for speed operation, external buzzer presence, channel selection, and system configuration.

[0018] According to an aspect of the illustrative embodiment, the at least one transmitter and at least one receiver are configured to pair for operational configurations selected from pitch and catch, cooperative and festoonless.

[0019] Another illustrative embodiment of this disclosure provides a transmitter for controlling the operation of a remotely controlled machine (RCM) device having one or more electrically controlled elements for moving at least one component associated with the RCM device. The transmitter includes: an antenna configured to wirelessly transmit radio frequency signals to one or more remote receivers paired with the transmitter; a configurable user input interface; a battery compartment configured to receive one or more batteries; a battery monitor / power management circuitry; and a processor connected to the antenna, the configurable user input interface, and the battery monitor / power management circuitry. The processor is configured to generate command signals for operating one or more of the electrically controlled elements in response to user manipulation of a corresponding element in the user input interface, and to send the command signals to the one or more remote receivers.

[0020] According to an aspect of the illustrative embodiment, the battery monitor / power management circuitry includes an electrically erasable programmable read-only memory (EEPROM).

[0021] According to an aspect of the illustrative embodiment, the battery monitor / power management circuit is programmed to monitor the current supplied by the one or more batteries and the voltage of the one or more batteries to determine the expected remaining operating time of the transmitter.

[0022] According to an aspect of the illustrative embodiment, the battery monitor / power management circuit is programmed to track the charging cycles, initial ampere-hour capacity, and current ampere-hour capacity of the one or more batteries.

[0023] According to an aspect of the illustrative embodiment, the battery compartment is configured for quick-connection to electrically connect one or more batteries to power any of the antenna, the processor, the battery monitor / power management circuitry, and other components in the transmitter.

[0024] According to an aspect of the illustrative embodiment, the transmitter further includes a USB-C connection.

[0025] According to aspects of the illustrative embodiments, the one or more batteries are charged via the USB-C connection (e.g., in the basic and standard transmitters described below). The standard transmitter, box transmitter, and mill-style box transmitter described below may have batteries that are charged via an external battery charger.

[0026] According to an aspect of the illustrative embodiment, the user can use the USB-C connection to access the transmitter's data log, which includes information selected from RCM device operation, fault occurrence, operation time, pairing configuration, and the status of one or more batteries.

[0027] According to an aspect of the illustrative embodiment, the transmitter further includes an indicator for indicating at least one of battery health, pairing status with the one or more receivers, and a fault.

[0028] According to an aspect of the illustrative embodiment, the transmitter further includes a pendulum switch mounted therein, and the processor is programmed to monitor the pendulum switch and disable the transmitter when the pendulum switch tilts a selected degree from a specified normal forward / backward position and a specified normal backward / forward position.

[0029] According to an aspect of the illustrative embodiment, the transmitter further includes a display. The processor is programmed to communicate information to the operator via the display, the information being selected from motion indication, maintenance mode, diagnostics, battery status, pairing selection, device name of each of the one or more receivers paired with the transmitter, emergency stop switch activation status, and tilt warning.

[0030] According to an aspect of the illustrative embodiment, the transmitter is arranged in a housing having a configurable toggle switch and an auxiliary switch selected from push-button switches, two-position toggle switches, three-position toggle switches, two- to ten-position configurable selector switches, and analog switches.

[0031] According to an aspect of the illustrative embodiment, the four-bit selector switch and the analog switch each have a dedicated input to the processor.

[0032] According to an aspect of the illustrative embodiment, the abdominal housing includes: an instrument surface on which the configurable toggle switch and the auxiliary switch are disposed; and a cage rod mounted relative to the exterior of the abdominal housing and extending from the instrument surface to prevent accidental activation of the toggle switch and the auxiliary switch in the event of a drop of the transmitter.

[0033] According to an aspect of the illustrative embodiment, the cage bar includes at least one curved portion that provides a hand grip portion that ergonomically supports the user's hand when operating the transmitter.

[0034] According to an aspect of the illustrative embodiment, the transmitter further includes RCM interface software to provide user configuration settings to the transmitter, and the RCM interface software communicates information to the processor to configure the radio frequency signals transmitted to the one or more receivers to implement the desired function of the motor control of the RCM device. For example, the receiver sets a radio frequency (channel selection) defining operation via a DIP switch on the receiver. The transmitter searches all frequencies (channels) to find a specific receiver.

[0035] Another illustrative embodiment of this disclosure provides a receiver for controlling the operation of a remotely controlled machine (RCM) device having one or more electrically controlled elements for moving at least one component associated with the RCM device. The receiver includes: an antenna configured to wirelessly receive radio frequency control signals from a remote transmitter; a power interface coupled to a power supply for the RCM device; a processor; and a plurality of configurable control outputs. The processor is configured to process signals received from a remote transmitter (TX) via the antenna and generate corresponding output signals to the one or more electrically controlled elements in the RCM device via at least one of the plurality of configurable control outputs to control the one or more electrically controlled elements in the RCM device.

[0036] According to an aspect of the illustrative embodiment, the receiver includes a Controller Area Network (CAN) bus interface for communicating with one or more external cards to control the operation of the RCM device.

[0037] According to an aspect of the illustrative embodiment, the external card can be mounted to the receiver via either a snap-on track or a housing mount.

[0038] According to an aspect of the illustrative embodiment, the external card includes outputs selected from the following: a relay output for operating an AC or DC RCM device, an analog output for controlling a variable frequency drive RCM device, and a latching relay output for maintaining the current state of the electric control unit during a power outage.

[0039] According to an aspect of the illustrative embodiment, each of the external cards includes at least one indicator of a fault occurrence.

[0040] According to an aspect of the illustrative embodiment, the receiver further includes at least one indicator operated by the processor to indicate the status of the receiver, the status being selected from power status, pairing status, CANbus status, and fault occurrence.

[0041] According to an aspect of the illustrative embodiment, the receiver further includes a DIP switch for configuring unique receiver settings for features selected from: configuration selection controlled by the DIP switch or configured via RCM interface software, relay output speed operation, external buzzer presence, channel selection, and system configuration.

[0042] One aspect of the illustrative embodiment provides a receiver for controlling the operation of a remote control machine (RCM) device having one or more electrically controlled elements for moving at least one component associated with the RCM device. The receiver includes: an antenna configured to wirelessly receive radio frequency signals; a power interface coupled to a power supply for the RCM device; a processor; and a plurality of card slots, each configured to removably receive an expansion card selected from a set of expansion cards having different types of control outputs. The plurality of control outputs connected to corresponding expansion cards in the plurality of card slots can be configured depending on the type of the RCM device and the operation to be controlled by the RCM device. The processor is configured to process signals received from a remote transmitter via the antenna and generate corresponding output signals to the one or more electrically controlled elements in the RCM device via at least one of the plurality of configurable control outputs to control the one or more electrically controlled elements in the RCM device. The configurable control outputs are selected from a plurality of control output types including: Type A relay contact outputs, Type C relay contact outputs, DC relay outputs, latching relay outputs, and analog outputs. In addition to the card slot expansion card, an external expansion card can also be connected to the receiver via the CAN bus interface for additional control outputs.

[0043] According to an illustrative embodiment, the number of configurable control outputs can be selected from a range of 1 to 48. Up to 256 control outputs can be selected via the external expansion card.

[0044] According to an aspect of the illustrative embodiment, the set of expansion cards includes expansion cards configured with corresponding of the plurality of control output types.

[0045] According to an aspect of the illustrative embodiment, the antenna receives radio frequency signals from the remote transmitter according to a 900 MHz wireless communication protocol.

[0046] According to an aspect of the illustrative embodiment, the receiver further includes a Controller Area Network (CANbus) interface.

[0047] According to an aspect of the illustrative embodiment, at least one of the expansion cards connected to the corresponding card in the plurality of card slots includes a Controller Area Network (CANbus) interface.

[0048] According to an aspect of the illustrative embodiment, the receiver further includes at least one of the following: an indicator selected from an optical indicator for indicating the diagnostic status of the receiver, an optical indicator mounted outside the receiver, an audible indicator mounted outside the receiver; and a connector configured to connect to the external audible indicator.

[0049] According to an aspect of the illustrative embodiment, the processor is configured to operate the indicator to output a first type of indication corresponding to the receiver being powered on, and to output a second type of indication corresponding to the receiver and the processor being operated to process signals received from the remote transmitter and generate corresponding output signals.

[0050] According to an aspect of the illustrative embodiment, the processor is configured to operate the indicator to output a third type of indication corresponding to the receiver being paired with the remote transmitter, and to output a fourth type of indication corresponding to at least one of receiver failure and the receiver being unable to pair with the remote transmitter.

[0051] According to an aspect of the illustrative embodiment, the receiver further includes a configurable power supply.

[0052] According to an aspect of the illustrative embodiment, the receiver according to claim 35 further includes at least one external card, which is mounted to the receiver via a snap-on rail or housing and is mounted via a CANbus interface.

[0053] According to an aspect of the illustrative embodiment, at least one external card can have an output selected from the following: a relay output for operating an AC RCM device, a DC RCM device, an analog output for controlling an RCM device with a variable frequency device, and a latching relay output for maintaining the current state during a power outage.

[0054] Additional and / or other aspects and advantages of the illustrative embodiments will be set forth in the description which follows, or will be apparent from the description, or may be learned by practice of the illustrative embodiments. Illustrative embodiments may include devices and methods of operation thereof having one or more of the foregoing aspects and / or one or more of the features and combinations thereof. Illustrative embodiments may include, for example, one or more of the features and / or combinations of the foregoing aspects set forth in the appended claims. Attached Figure Description

[0055] The above and / or other aspects and advantages of the illustrative embodiments will be more readily understood from the following detailed description taken in conjunction with the accompanying drawings.

[0056] Figure 1 Describe an example standard radio control system for radio-controlled machinery (RCM) devices (such as cranes).

[0057] Figure 2 Describe an example of a crane control system for launching and capturing data.

[0058] Figure 3 Describe examples of collaborative or non-tethered crane control systems.

[0059] Figure 4A and 4B These are top and bottom perspective views of an example handheld shape factor of a basic transmitter constructed according to an example embodiment.

[0060] Figure 5A , 5B 5C and 5C are respectively top, side, and bottom views of the basic transmitter according to the example embodiment.

[0061] Figure 6A This is a block diagram of a basic transmitter based on an example embodiment.

[0062] Figure 6B This is a block diagram of a computer having an RCM interface application that can be connected to a basic transmitter, according to an example embodiment.

[0063] Figure 7 This is a block diagram of a battery monitor / power management circuit deployed in a basic or standard transmitter according to an example embodiment.

[0064] Figure 8A and 8B These are top and bottom perspective views of an example handheld shape factor of a standard transmitter constructed according to an example embodiment.

[0065] Figure 9A , 9B 9C and 9C are respectively the top view, side view and bottom view of the standard transmitter according to the example embodiment.

[0066] Figure 10 This is a block diagram of a standard transmitter based on an example embodiment.

[0067] Figure 11A , 11B 11C and 11C are respectively the top view, bottom view and side perspective view of the exemplary box transmitter constructed according to the exemplary embodiment.

[0068] Figure 12 This is a top view of the user interface of the box transmitter according to an example embodiment.

[0069] Figure 13 This is a block diagram of a box-type transmitter according to an example embodiment.

[0070] Figure 14 This is a block diagram of a battery monitor / power management circuit deployed in a box-type or mill-type box-type transmitter according to an example embodiment.

[0071] Figure 15A and 15B These are top and bottom perspective views of an example rolling mill-type box launcher constructed according to the example embodiments.

[0072] Figure 16 This is a top view of the user interface of a rolling mill-type box launcher according to an example embodiment.

[0073] Figure 17 This is a block diagram of a rolling mill type box launcher according to an example embodiment.

[0074] Figure 18A , 18B 18C and 18C are respectively the front view, rear view and side view of the example housing of a standard receiver or digital receiver according to the example embodiments.

[0075] Figure 19 This is a block diagram of a standard receiver according to an example embodiment.

[0076] Figure 20 This is a block diagram of a digital receiver according to an example embodiment.

[0077] Figure 21A , 21B 21C and 21C are respectively the front view, side view and rear view of the example housing of the scalable receiver according to the example embodiment.

[0078] Figure 22 This is a block diagram of a scalable receiver according to an example embodiment.

[0079] Figure 23 This is a block diagram of a DC relay output expansion card that can be deployed with an expandable receiver, according to an example embodiment.

[0080] Figure 24 This is a block diagram of a Type A output expansion card that can be deployed with an expandable receiver, according to an example embodiment.

[0081] Figure 25 This is a block diagram of a Type-C output expansion card that can be deployed with an expandable receiver, according to an example embodiment.

[0082] Figure 26 This is a block diagram of a latched output expansion card that can be deployed with an expandable receiver, according to an example embodiment.

[0083] Figure 27 This is a block diagram of an expansion card with analog output that can be deployed with an expandable receiver, according to an example embodiment.

[0084] Figure 28A and 28B This is a diagram of a corresponding example implementation of a scalable receiver with different expansion cards or an auxiliary housing having outputs in a remote crane control system according to an example embodiment.

[0085] Figure 29This is a diagram illustrating an example implementation of a digital or standard transmitter that communicates with a digital or standard receiver deployed in a remote control relay cabinet in a remote crane control system, according to an example embodiment.

[0086] Figure 30 This is a diagram illustrating an example implementation of a digital or standard transmitter that communicates with a digital or standard receiver in a receiver cabinet deployed in a remote crane control system to control a variable frequency drive (VFD).

[0087] Figure 31 This is a diagram illustrating an example implementation of a digital or standard transmitter communicating with a digital or standard receiver connected to the customer connection via a multi-core cable in a remote control customer connection system constructed according to an example embodiment.

[0088] Figure 32A , 32B 32C is a side view and a front perspective view of a handheld battery charger according to an example embodiment, wherein Figure 32B The display shows a handheld battery charger that does not include battery charging. Figure 32C The handheld battery charger with battery charging capability is on display.

[0089] Figure 33 It is a battery charger constructed according to an example embodiment to charge multiple batteries for a belly box launcher or a mill-type belly box launcher.

[0090] Throughout the accompanying drawings, the same reference numerals should be understood to refer to the same elements, features, and structures. Detailed Implementation

[0091] Reference will now be made in detail to the illustrative embodiments depicted in the accompanying drawings. The embodiments described herein are illustrated by way of example, but not limitation, of the illustrative embodiments. The exemplary embodiments described herein relate to the radio control of cranes (e.g., cranes for steel mill environments and mines), but can be used in other applications, such as controlling other types of mobile equipment, and in other environments such as railway systems.

[0092] This document describes an improved radio control system in which various examples of radio transmitter and receiver embodiments include a variety of boards and expansion cards from which users can choose to create customized radio systems for their desired Radio Control Machine (RCM) applications. Controller Area Network (CAN) communication is provided for all receiver boards to allow them to communicate with each other, creating a user-configurable and customizable receiver system. Compared to the radio units in existing radio control systems, these radio transmitters feature improved battery packs and chargers. These radio transmitters and receivers also feature USB connectivity for accessing data logs and programming, as well as other advantageous features. Handheld radio transmitters have useful indicators (e.g., one or more tri-color LEDs) for indicating battery status and pairing status, and may have optional tri-color LEDs to indicate operational configuration. Radio receivers also have useful indicators (e.g., one or more tri-color LEDs) for indicating pairing status, and LEDs for indicating fault conditions.

[0093] exist Figure 1 The standard radio crane control system 10a is depicted. The radio crane control system 10a consists of a portable transmitter (hereinafter referred to as transmitter (Tx)) 14 that generates control signals and receiving equipment (hereinafter referred to as receiver (Rx)) 16, each permanently or removably mounted on the crane and electrically connected to the crane's motor control unit 20. As described below, the control system 10a may have a variety of load handling options and the ability to control multiple hoists simultaneously. The transmitter 14 is constructed for durability in harsh environments and is made of industrial-strength materials for years of use in the most severe conditions. Figure 1 The standard radio crane control system 10a allows dedicated communication between a transmitter 14 and a receiver 16, and requires the termination of communication between the original transmitter and receiver pair before pairing with another receiver 16.

[0094] The radio control system 10 described herein, based on an example embodiment, uses a 900 MHz radio band and associated signaling technology (e.g., frequency hopping spread spectrum (FHSS) modulation from 902.971 to 926.653 MHz, with AES ≥ 128-bit encryption). A receiver 16 is connected to the crane's control unit. A switch, lever, or button interface on the transmitter 14 creates control signals (e.g., specified pulse combinations) that are transmitted to the receiver 16. The receiver 16 then decodes the control signals (e.g., pulses) and transmits the pulses to the crane's motor controller.

[0095] Remote control of the crane via transmitter 14 allows the operator to be involved in lifting and attaching loads. Using a fixed-position control unit might require two people, or one person moving back and forth between the load and the control unit. Using a remote portable tow hook, the operator can participate in load lifting and handling.

[0096] At the other end of the crane control system is receiver 16. Receiver 16 can be pre-wired with a section of cable and mounting hardware for quick installation onto crane 12 and associated motor controller 20. Receiver also features onboard diagnostics and output LEDs to provide system status information. Receiver 16 is fully enclosed to provide protection in the harshest indoor or outdoor environments, preventing dust, mist, or water from entering the receiver.

[0097] The following are some terminology definitions used herein to describe exemplary embodiments of the improved radio control system 10.

[0098] AC: AC stands for alternating current (e.g., current that periodically reverses its direction). The standard current used by U.S. utilities is 60 cycles per second, while in Europe and other parts of the world it is 50 cycles per second.

[0099] Antenna: A physical structure for capturing and / or transmitting radio electromagnetic waves. The antenna on a transmitter is preferably internal.

[0100] Cable tray: A cable tray is the track for a crane.

[0101] DC: DC is direct current (e.g., current flowing in only one direction).

[0102] Deadman switch: A switch designed to activate when a human operator becomes incapacitated.

[0103] Discovery: The process by which the transmitter sends out a notification and collects a list of all receivers that respond.

[0104] Towing: A specialized suspension system designed to suspend, support, and move hoses and cables in a working environment. A towing-free system allows one transmitter to control two different functions on two receivers. Example: One receiver controls the cable tray, and the other controls the trolley.

[0105] Elevator: An elevator is used to lift loads up and down.

[0106] Pairing: A form of information registration used to connect devices. After pairing is complete, the two devices can communicate with each other.

[0107] Drop and Capture: Crane operation that allows two operators to efficiently move loads across long work areas. Radio transmission from one operator to another is seamless. One operator will lift the load and move the crane along the work area to the other operator.

[0108] Radio control system: The radio crane control system includes at least one transmitter and at least one receiver.

[0109] RCM: Radio Control Machine (RCM)

[0110] RCM Configuration Generator: The RCM Configuration Generator is an application used to create configuration files. These files describe the mapping from transmitter motion speed / direction selection to receiver control outputs.

[0111] RCM Interface: The RCM interface is an application that allows users to interface with, manipulate, and visualize the details of an RCM device.

[0112] Receiver: The receiver interprets the desired action suggested by the transmitter and translates the information into output control for the RCM device (e.g., a crane).

[0113] Standard: As used in this disclosure, "standard" in relation to a transmitter or receiver, or a card or board deployed in a transmitter or receiver, refers to a set of features that distinguish the transmitter or receiver from, for example, another transmitter or receiver (e.g., according to the corresponding exemplary embodiments described herein, a standard transmitter has a different set of features compared to a basic transmitter, and a standard receiver has a different set of features compared to a digital receiver according to the corresponding exemplary embodiments described herein). As used herein, "standard" does not mean "conventional".

[0114] Collaborative lifting: Collaborative lifting is also a widely used operation process in the industrial field. In this process, the operator can handle more than one crane or lift at a time to lift huge loads.

[0115] Transceiver: An electronic circuit that transmits and receives wireless data.

[0116] Transmitter: The transmitter is the operator interface for controlling the movement of RCM devices (such as cranes).

[0117] Transfer switch: A device that allows for the safe connection or disconnection of different power sources from electrical loads.

[0118] Car: A car is a vehicle that travels on a bridge.

[0119] In crane operation, some suspension controls allow for operations beyond typical basic lifting controls. More complex crane installations may require additional features. For example, according to an exemplary embodiment, the belly box transmitter may have a button configured as an A / B selector switch (AB), such as a three-position selector switch, which allows an operator to switch operation between two trolleys / lifts (A, B, or both) located on a single cable tray. The operator can easily identify which trolley / lift on the crane is active by the position of the A / B selector switch.

[0120] Figure 2 This describes the topology of the launch and capture system used in the launch and capture crane control system 10b, which allows communication between more than one transmitter and one receiver. During initial setup, each transmitter 14 is paired with a receiver 16. During operation, only one transmitter 14 can communicate with the receiver 16 at a time. Transmitters 14 in initial operation must release / launch communication with the receiver so that another transmitter can capture and communicate with the receiver. At any given time, two transmitters cannot simultaneously control the same receiver.

[0121] According to other example embodiments, the transmitter 14 and receiver 16 of this disclosure can be configured for cooperative or non-delayed operation, for example, as Figure 3 This is illustrated in the towing-free / cooperative crane control system 10c shown. The cooperative system topology allows one transmitter 14 to simultaneously control the same function of two receivers 16. Therefore, this operation can be used to operate two cooperating receivers 16 to complete an operation. The cooperative system topology also allows two operators to independently or simultaneously control two bridge cranes or trolleys / lifts using a three-position selector switch. One operator can maximize the capacity and lifting capacity of two bridge cranes, or two users can operate each bridge crane independently.

[0122] exist Figure 3 The diagram also illustrates a toggle-free system topology. A toggle-free system allows one transmitter 14 to control two different functions on two receivers 16. For example, one receiver 16 can be configured to control a cable tray, and another receiver 16 can be configured to control a trolley. For instance, because the toggle-free system 10c allows an operator to select multiple receivers at once, an operator can simultaneously or independently control up to two cable trays and four trolleys / lifts. This simplifies installation by eliminating toggle-to-cable tray control.

[0123] The improved radio control system 10 described herein based on exemplary embodiments includes a catalog or platform with different types of transmitters 14 and different types of receivers 16 with different capabilities and characteristics, from which a user can select to design a customized radio control system for their specific application.

[0124] The exemplary embodiments described herein facilitate and universally adapt the design and customization of the radio control system 10 by providing users with a choice of various advantageous form factors for the transmitter 14 and receiver 16, as well as corresponding features of the exemplary embodiments of the transmitter and receiver described herein. Furthermore, convenient configuration is facilitated by features of the exemplary embodiments, such as DIP switches, RCM configuration generator applications, and RCM interface software, and other features. The versatility of the receiver output for controlling different types of RCM devices in different applications is provided by different receiver form factors and expansion cards, as well as CANbus connectivity and other features. Therefore, the exemplary embodiments described herein allow users to conveniently design their remote-controlled crane system 10, i.e., for example, a standard crane control system 10a, a drop-and-capture crane control system 10b, a cooperative crane control system 10c, or a towless crane control system 10c, depending on their specific application and preferred system topology.

[0125] According to an example embodiment, the platform of the improved radio control system 10 is equipped with at least four different types of transmitters; namely, a basic transmitter 14a, a standard transmitter 14b, a box transmitter 14c, and a mill-type box transmitter 14d, which will be further described below.

[0126] According to an example embodiment, the platform of the improved radio control system is equipped with at least three different types of receivers: a standard receiver 16a, a digital receiver 16b, and an expandable receiver 16c. The expandable receiver 16c is configured to operate via a CANbus interface with various external expansion cards, including (but not limited to) DC crane relay output external cards [slot A (ECDR) 22a], type A output external cards [slot A (ECFA) 22b], type C output external cards [slot A (ECFC) 22c], latched output external cards [slot Latched Output External Card (ECLO) 22d], and an external card 22e with analog outputs, as further described below. The expandable receiver operates with (but not limited to) type A relay output card slots CFSA, CSFC, and analog interface card slots CSAI.

[0127] The improved radio control system 10 is designed to utilize a uniform program for all transmitter 14 and receiver 16 types within its platform. In other words, each transmitter 14 can operate on the same transmitter program, and each receiver 16 can operate on the same receiver program. The improved radio control system 10 offers the flexibility to use transmitters 14 with similarly configured receivers 16 (e.g., for drop and capture operations). As stated above, not every transmitter 14 or receiver 16 has the same capabilities. The types of transmitters 14 and receivers 16 used within a particular radio control system 10 will depend on the required application.

[0128] According to an example embodiment, the improved radio control system 10 may have a graphical user interface (GUI display 32) on the transmitter 14, which allows configuration of the transmitter actuators and corresponding receiver outputs. The GUI configuration file can be used to select and locate the transmitter actuators, receiver outputs, and system diagram.

[0129] Some transmitter 14 types provided in the platform of the improved radio control system 10 have a GUI display 54 that provides feedback on certain operations, top-level fault conditions, and a first-in-first-out (FIFO) log, which provides fault and actuator inputs. Some receiver 16 types provided in the platform of the improved radio control system 10 may also have a GUI display that provides the same type of information as the transmitter. However, the fault feedback provided by the receiver 16 is more detailed to help maintenance personnel isolate and troubleshoot specific problems. The actuator logs of the transmitter 14 and receiver 16 can be used for post-incident investigation to verify user input against receiver 16 output. All recorded information may have a time and date stamp to determine when the event occurred.

[0130] Transmitter 14 and receiver 16 are provided with a basic configuration or a customer-specific configuration using a crane control feature requirements table. The transmitter and receiver can be modified by the system user using a button interface or the crane control configuration software described below. The transmitter / receiver configuration can be stored using the crane control configuration software. The system is supplied with a default configuration at the factory. The system user can modify the configuration via the button interface or the crane control configuration software.

[0131] The default standard / drop and capture crane control system 10b has two transmitters 14 paired with a single receiver 16. The default standard crane control system 10a has a configuration in which the transmitters 14 will be paired with the receiver 16 in default settings. Each transmitter 14 has repeating configuration settings. Therefore, operation can include standard operation or drop and capture operation. The basic transmitter 14a and the standard transmitter 14b have this configuration.

[0132] The collaborative crane control system 10c has a transmitter 14 paired with two receivers 16. The receivers 16 operate identically. The transmitter 14 uses the same active concurrent control to provide the same complementary output from each receiver 16. The standard transmitter 14b has this configuration option. The basic transmitter 14a does not have this configuration option.

[0133] The no-tether crane control system 10c has a transmitter 14 paired with two receivers 16. The receivers 16 of the no-tether crane control system have different operations. The transmitter 14 uses different activation controls on the output from each receiver 16. The standard transmitter 16b has this configuration option. The basic transmitter 16a does not have this configuration option.

[0134] Due to the complexity of the belly box transmitter 16c, the radio control system 10 may have a default system configuration, or the transmitter 14 / receiver 16 combination may alternatively employ a complete crane control feature requirements table for more customized settings.

[0135] The catalog or platform of the improved radio control system 10 controlled according to exemplary embodiments of this disclosure includes components for creating DC or AC radio systems for industrial and commercial markets. The mill-type box transmitter 14d and related equipment are particularly useful in the industrial control market segment.

[0136] The transmitter 14 and receiver 16 of the exemplary embodiments of this disclosure operate according to a common software interface and include (but are not limited to) crane control configuration software, which includes a radio control machine (RCM) configuration generator 26 and a radio control machine (RCM) interface 28.

[0137] The Radio Control Machine (RCM) configuration generator 26 is an application used to create a configuration file 26a. This configuration file 26a describes the mapping (e.g., bit functions) from transmitter motion speed / direction selection to receiver control outputs. Configuration file 26a is used by the Radio Control Machine Interface 28 application, which transmits configuration settings to transmitter 14.

[0138] The Radio Control Machine (RCM) interface 28 is an application that allows users to access, manipulate, and visualize the details of a radio control machine device. For example, the RCM interface 28 application can be implemented as, for example, a Windows operating system application 28. The user can then connect the radio control machine device 12 to their Windows-based computer 24 via a USB connection and then manipulate / interact with the RCM device 12. The RCM interface 28 application tasks may include (but are not limited to) transmitting configuration settings, retrieving operation logs, and initiating equipment diagnostics.

[0139] Now refer to Figures 4A to 7 The example of basic transmitter 14a is described. Basic transmitter 14a is configured for use in a commercial environment and typically contains only the basic features required to operate a crane, and therefore is consistent with the following references. Figures 8A to 10 The standard transmitter 14b described and the following references Figures 11A to 17 The described box transmitter 14c is cheaper than the rolling mill box transmitter 14d, and the implementation of the remote crane control system 10 is simpler. The basic transmitter 14a features buttons covered with polyester film (Mylar) and LED indicators for power, communication, A and B receiver status, and fault events for operational indication. The basic transmitter is primarily designed to be compatible with the following references. Figures 18A to 19 The standard receiver described works together, but can also be operated as described in the reference below. Figures 21A to 22 The scalable receiver described and the following references Figure 20 The digital receiver described.

[0140] Figure 4A and 4B These are top and bottom perspective views of an example handheld shape factor of a basic transmitter 14a constructed according to an example embodiment. Figure 5A , 5B 5C and 5C are top, side, and bottom views of the basic transmitter 14a according to the example embodiment, respectively. The handheld basic transmitter is configured to allow the operator (a) to hold the basic transmitter 14a with one hand while strapping the transmitter to the operator's wrist, and (b) to access and use all the buttons on the user interface 30a on the handheld basic transmitter, while the handheld basic transmitter is conveniently and comfortably placed in the operator's palm.

[0141] As described below, the battery-operated handheld basic transmitter 14a has button inputs 32 and indicators 34 (e.g., LED status indicators) on its user interface 30a. These buttons 32 include three pairs of dual-speed motions 32a, an additional user-defined single-action instantaneous pair 32b, a start button 32c, and a stop button 32d. The LED status indicator 34 is configured to report battery status, communication, and A / B receiver status. The basic transmitter 14a wirelessly transmits the status of its buttons 32 to a line-powered receiver 16, which then controls the electrical outputs associated with the operating crane or other mobile equipment 12.

[0142] Figure 6 is a block diagram of a basic transmitter 14a according to an exemplary embodiment. The basic transmitter 14a includes a processor 36 and a transceiver module 38. The transceiver module 38 has a built-in antenna 40 to prevent damage and provide sufficient support to ensure that the antenna does not detach from the transceiver 38 during severe shock loads. The basic transmitter 14a further includes a lithium battery 42, which can... Figure 5C The quick-connect battery compartment is indicated at point 44 in Figure 6. The battery is charged via a USB-C connection as indicated by computer / charging interface 46 in Figure 6. (See reference) Figure 7 The description provides a battery monitor / power management circuit 52a. Standard and basic transmitters 14a and 14b may also have a battery that can be charged via a separate remote charger module.

[0143] Continue to refer to Figure 5A , 5B The 5C and 6, basic transmitter 14a has 10 buttons for crane operation, including:

[0144] ● A start / horn button 32c is used to initiate the operation of the crane and sound the horn.

[0145] ● A stop button 32d provides dual functions: (a) upon startup, it momentarily connects the battery power to the processor via a normally open connection, which initiates the processor startup and activates the latch circuit that maintains the battery connection; and (b) while the latch circuit is active, if the processor detects the closure of the stop button, it will terminate all currently active functions.

[0146] ● The three pairs of 2-speed buttons indicated at 32a are used to operate the crane in three directions.

[0147] ● Two configurable auxiliary buttons are indicated at 32b.

[0148] For example, the stop button can be pressed and held to power on the basic transmitter, and pressed again at any time to stop the operation of the currently selected receiver A or B. The first three pairs of buttons control the movement of the lift / trolley / cable tray by default. The A / next / Aux-1 configurable auxiliary button can be used to select receiver A or control Aux1 or the second lift to rise. The B / enter / Aux-2 configurable auxiliary button can be used to select receiver B or control Aux2 or the second lift to descend. These 10 buttons are also used for transmitter self-diagnosis, such as button contact jamming or open circuit.

[0149] Continue to refer to Figure 5A , 5B The 5C and 6 basic transmitters have four indicators 34 (e.g., LEDs) for user indication, such as:

[0150] ● An indicator for indicating the pairing mode / wireless communication with the receiver (e.g., a tri-color LED, where green indicates communication, solid red indicates no communication, and flashing red indicates a malfunction).

[0151] ● An indicator (e.g., a tri-color LED) used to indicate battery health.

[0152] ● An indicator for receiver A (e.g., Figure 3 (RX1 in the example). For example, a tri-color LED can be used, where off indicates that it is not connected to receiver A, orange indicates that receiver A is selected but not active, green indicates that receiver A is active, and red indicates a fault.

[0153] ● An indicator for receiver B (e.g., Figure 3 (RX2 in the example). For example, a tri-color LED, where off indicates that it is not connected to the B receiver, orange indicates that the B receiver is selected but not active, green indicates that the B receiver is active, and red indicates a fault.

[0154] The basic transmitter 14a is equipped with a DIP switch 50 containing an array of DIP switch settings, which can be accessed, for example, via a battery compartment 44 on the back of the transmitter 14a (e.g., to configure unique settings for the transmitter). For example, the DIP switch 50 settings can be used to define the function of the fourth row of buttons on the basic transmitter (e.g., motion or assist), where motion is bidirectional single-speed operation. Assist functions can include A / B transmitter functionality, single relay contact enable function, and momentary / toggle on-off. The DIP switch settings can also be used for inactivity time selection.

[0155] The default configuration of the basic transmitter 14a assigns the elevator / trolley / bridge movement to the first three pairs of buttons 32a. As stated above, the fourth pair of buttons 32b is defined by a DIP switch on the back of the transmitter. The start and stop buttons 32c and 32d are not configurable. If needed, the RCM configuration generator 26 can be used to reconfigure the first three pairs of buttons 32a of the transmitter 14a for different functions, and then the configuration file can be transmitted to the transmitter 14 and the receiver 16 via the RCM interface 28.

[0156] Figure 7 This is a block diagram of an example battery monitor / power management circuit 52ab deployed in a basic transmitter 14a or a standard transmitter 14b according to an example embodiment. The battery monitor / power management circuit 52ab has a processor 53 (e.g., EEPROM) included in its battery assembly to track charging cycles, initial ampere-hour capacity, and current ampere-hour capacity. The basic transmitter 14a is configured to monitor the current supplied by the battery and the voltage of the battery 42 to determine the expected remaining operating time of the transmitter. The start-up operation of the basic transmitter 14a can be triggered by activating the stop button 32d for 3 seconds. At this time, the latch circuit 57 connects the battery 42 to the basic transmitter 14a for operation. During power-off, the processor 36 can reset the latch 57 and disconnect the battery power from the basic transmitter before the power supply capacitor 55a discharges, to achieve proper power-off sequencing. After the power-off sequence, the stop button 32d needs to be cycled to initiate transmitter operation. The basic transmitter 14a charges the battery 42 via a USB-C connection 46 during installation. During charging operation, the USB-C connection 46 charges the battery 42 and supplies power to the basic transmitter 14a for efficient battery charging cycles. At the start of a charging cycle, the processor 36 detects the USB-C voltage and measures the no-load battery voltage. After the processor determines the no-load battery voltage, it connects the USB-C port 46 to the battery 42, as indicated at 59, to initiate a charging cycle. The battery can also be charged via an external battery charger assembly.

[0157] By way of example, the basic transmitter 14a can analyze the remaining battery percentage and provide appropriate indications at the following power levels:

[0158]

[0159] The basic transmitter will not be allowed to operate when the remaining battery charge is below 10%. The basic transmitter 14a can also analyze the percentage of the battery 42's state of charge and provide appropriate indications at the following charge levels:

[0160]

[0161] The basic transmitter has a USB-C connection, which can be externally connected to obtain the device's data log. The log can be accessed through the RCM configuration generator to obtain information about RCM device operation, fault occurrences, operation time, pairing configuration, and battery status.

[0162] The processor in the basic transmitter analyzes and reports faults during normal operation and indicates a fault by illuminating a solid red communication LED. Receiver faults are indicated by either LED A or B also illuminating a solid red LED. To recover from a fault, the operator typically resolves the original fault. For some faults, the operator performs a system startup procedure to continue operation. For example, the processor may detect a communication loss (e.g., the transmitter is currently communicating with the receiver but has not received an acknowledgment message within 1 second). To restore radio communication after a communication loss, the operator must press the start / horn button. The processor may also detect invalid combinations of switches. For example, if an invalid combination of transmitter switches is detected, the transmitter will disable the faulty motion. When this error is cleared, communication LED 34 will return to normal, and normal operation can be resumed for this motion. The processor may also detect receiver faults (e.g., if the transmitter is currently communicating with receiver 16 and the receiver reports an error). Actions to mitigate this type of failure are typically taken by receiver 16, and further troubleshooting is performed by evaluating the receiver separately.

[0163] According to another embodiment of this disclosure, the platform of the improved radio control system 10 includes another shape factor for the transmitter, which is Figures 8A to 10 The standard transmitter 14b is shown in the image. Figure 8A and 8B These are top and bottom perspective views of an example handheld shape factor of a standard transmitter 14b constructed according to an example embodiment. Figure 9A , 9B 9C and 9C are respectively the top view, side view and bottom view of the standard transmitter 14b according to the example embodiment. Figure 10 This is a block diagram of a standard transmitter 14b according to an example embodiment. The standard transmitter 14b has features deployed in a basic transmitter and described above. Figure 7 The same battery monitor / power management circuit 52ab is described.

[0164] refer to Figures 8A to 9CFor example, the standard transmitter 14b can be used in a commercial environment and includes an actuator for operating a crane. The standard transmitter 14b has elastomeric covered buttons indicated at 32a and 32b, a start / horn button 32c on a recessed side of the housing, and an emergency stop twist lock button 32d. The standard transmitter 14b includes indicators 34 (e.g., LED indicators) for battery health and communication. The standard transmitter 14b is primarily designed to operate with the standard receiver 16a, but can also be used with the following references. Figures 21A to 22 The scalable receiver 16c described and the following references Figure 20 The described digital receiver 16b operates together. The handheld standard transmitter 14b is configured to allow the operator (a) to hold the standard transmitter in one hand while attaching it to, for example, the operator's wrist or waist, and (b) to access and use all the buttons 32 on the handheld standard transmitter, while the handheld standard transmitter is conveniently and comfortably placed in the operator's palm.

[0165] As described below and Figure 10 As shown, the battery-operated handheld standard transmitter 14b has a user interface 30c, which includes button inputs indicated at 32a and 32b, a status indicator 34, a display 34 (e.g., an OLED display), and a twist lock emergency stop button 32d. Buttons 32 include three pairs of dual-speed motions 32a, an additional user-defined pair of dual-speed motions 32b, a start button 32c, and a twist lock emergency stop button 32d. The status indicator 34 is configured to report the battery 42 status and radio communication status. The standard transmitter 14b wirelessly transmits the status of its buttons 32 to a line-powered receiver 16, which then controls the electrical outputs associated with the operating crane or other mobile equipment 12.

[0166] refer to Figure 10 The standard transmitter 14b includes a processor 36 and a transceiver module 38. The transceiver module 38 has an internally mounted antenna 40 to prevent damage and provide sufficient support to ensure that the antenna does not detach from the transceiver module 38 during severe shock loads. The standard transmitter 14b further includes a lithium battery 42, which can... Figure 9C The battery compartment 44 is indicated by four quick-connect links for battery replacement. Battery 42 is connected via... Figure 10 The battery is charged via a USB-C connection indicated by computer / charging port 46. The battery can also be charged via an external battery charger assembly. (See reference) Figure 7 The description provides a battery monitor / power management circuit. The standard transmitter may also have a battery 42 that can be charged via a separate remote charger module, as shown below. Figures 32A to 32C The battery charger 158 is described.

[0167] Continue to refer to Figure 9A ,9B 9C and 10, the standard transmitter 14b has 10 buttons for crane operation, including:

[0168] ● A start / horn button 32c is used to initiate the operation of the crane and sound the horn.

[0169] ● An emergency stop twist lock button 32d provides dual functions: (a) upon startup, it momentarily connects the battery power to the processor 36 via a normally open connection, which initiates the processor startup and activates the latch circuit that maintains the battery connection; and (b) while the latch circuit is active, if the processor 36 detects the closure of the stop button, it will terminate all currently active functions.

[0170] ● Three pairs of two-speed buttons 32a are used to operate the crane in three directions. The speed settings are implemented via mechanical shifting.

[0171] ● Two configurable 2-speed assist buttons 32b.

[0172] For example, the emergency stop button 32d can be activated at any time to stop the operation of the currently selected receiver 16, and can also be used during system startup. The start / horn button 32c can be pressed to initiate the operation of the crane or moving equipment, to sound the horn, and as a selection button in transmitter maintenance mode. The first three pairs of buttons 32a can control the movement of the lift / trolley / bridge by default. One of the buttons indicated at 32b can be an Aux-1 / Next configurable auxiliary button for selecting or controlling the ascent of Aux1 or the second lift among receivers 16, and as a Next selector in transmitter maintenance mode. Another button indicated at 32b can be an Aux-2 configurable auxiliary button for controlling the descent of Aux2 or the second lift. These 10 buttons indicated at 32a to 32d are also used for self-diagnosis of the transmitter 14b, such as button contact jamming or open circuit.

[0173] Continue to refer to Figure 9A , 9B 9C and 10, the standard transmitter 14b has two LEDs 34 for user indication, for example:

[0174] ● A tri-color LED for indicating pairing mode / wireless communication with the receiver (e.g., green for communication, solid red for no communication, and flashing red for malfunction); and

[0175] ● A tri-color LED used to indicate battery health.

[0176] The standard transmitter 14b has a pendulum or tilt switch 56, which is installed inside the transmitter and configured to disable the standard transmitter when it tilts 30° from its normal forward or backward position. The standard transmitter has a display 54 for conveying detailed information to the operator, such as (but not limited to) motion indication, maintenance mode / diagnostics, battery status, pairing selection, currently paired device name, emergency stop activation, and tilt warning.

[0177] The standard transmitter 14b is equipped with a DIP switch 50 containing an array of DIP switch settings, which can be accessed, for example, via a battery compartment 44 on the back of the transmitter 14b (e.g., for configuring unique settings for the transmitter). For example, the DIP switch settings can be used to define the function of the fourth row of buttons on the standard transmitter (e.g., motion or assist), where motion is bidirectional and operates at up to two speeds. Assist functions can include A / B transmitter functionality, single relay contact enable function, and lockout function. The DIP switch 50 settings can also be used for system configuration, inactivity time selection, and tilt switch activation.

[0178] The default configuration of the standard transmitter 14b assigns the elevator / trolley / bridge movement to the first three pairs of buttons indicated at 32a. As stated above, the speed button pairs indicated at 32b are defined by the DIP switch 50 on the back of the transmitter. The start and torque lock emergency stop buttons 32c and 32d are not configurable. The RCM configuration generator 28 can be used to reconfigure the first three pairs of buttons 32a of the transmitter 14b for different functions, and then, in accordance with the description above regarding the basic transmitter 14a, and Figure 6B The same method shown in the figure transmits the configuration file 26a to the transmitter 14b and the receiver 16 via the RCM interface 28.

[0179] Figure 7 This is a block diagram of an example battery monitor / power management circuit 52ab deployed in a basic transmitter 14a or a standard transmitter 14b according to an example embodiment. The battery monitor / power management circuit 52ab has a processor 53 (e.g., EEPROM) included in its assembly, such as... Figure 7As shown, the system tracks charging cycles, initial ampere-hour capacity, and current ampere-hour capacity. The standard transmitter 14b is configured to monitor the current supplied by the battery and the voltage of battery 42 to determine the transmitter's remaining expected operating time. The standard transmitter's start-up operation can be triggered by activating the emergency stop button 32d. At this time, latch circuit 57 can connect the battery to the standard transmitter 14b for operation. During power-off / overdue periods, processor 53 can reset the latch and disconnect the battery power from the standard transmitter 14b before the power supply capacitor 55a discharges, achieving proper power-off sequencing. During installation, the standard transmitter 14b charges battery 42 via USB-C connection 46. During charging operation, USB-C connection 46 charges battery 42 and supplies power to the standard transmitter 14b for efficient battery charging cycles. At the start of a charging cycle, processor 53 detects the USB-C voltage and measures the no-load battery voltage. After processor 53 determines that the battery has no load voltage, processor 53 connects USB-C 46 to battery 42, as indicated at 59, to initiate a charging cycle.

[0180] As an example, the standard transmitter 14b can analyze the remaining battery percentage and provide appropriate indications at the following power levels:

[0181]

[0182] The standard transmitter 14b will not be allowed to operate when the remaining battery charge is below 10%. The transmitter can also analyze the battery's state of charge percentage and provide appropriate indications at the following charge levels:

[0183]

[0184] The standard transmitter 14b has a USB-C connection 46, which can be externally connected to a standard transmitter (e.g., via battery compartment 44) to obtain the device's data log. The log can be accessed via RCM interface software (e.g., RCM configuration generator 26) to obtain information about RCM device 12 operation, malfunctions, operating time, pairing configuration, and battery status.

[0185] The processor 36 in the standard transmitter 14b analyzes and reports faults during normal operation and indicates the fault by illuminating the communication LED 34. For transmitter faults, the communication LED 34 is constantly lit, or for receiver faults, it flashes intermittently. Operation will stop, and the display 54 will provide detailed information about the nature of the fault. To recover from a fault, the operator typically resolves the original fault. For some faults, the operator performs a system startup procedure to continue operation. For example, the processor 36 may detect communication loss (e.g., transmitter 14b is currently communicating with receiver 16 and has not received an acknowledgment message within 1 second). To restore radio communication after a communication loss, the operator must press the start / horn button 32c. The processor 36 may also detect invalid combinations of switches. For example, if an invalid combination of transmitter switches is detected, transmitter 14b will disable the faulty movement. When this error is cleared, the communication LED 34 may return to normal, and normal operation of the movement will resume. The processor 36 may also detect the activation of the tilt switch 56. As stated above, the standard transmitter is equipped with a tilt switch 56, which must be held at <30 degrees to maintain function. To restore radio communication after the tilt switch 56 is activated, the operator must return the standard transmitter to the appropriate angle and press the start / horn button 32c. The processor 36 can also monitor receiver 16 for malfunctions (e.g., if transmitter 14b is currently communicating with receiver 16 and receiver 16 reports an error). Actions to mitigate this type of failure are typically taken by receiver 16, and further troubleshooting is performed by evaluating the receiver separately.

[0186] Compared with the handheld shape factor of the basic and standard transmitters 14a and 14b described above (e.g., reference), Figure 4A and 4B as well as Figure 8A and 8B In contrast, another shape factor of the transmitter 14 in the improved radio control system 10 is the belly box shape factor, which will now be referred to... Figures 11A to 11C The belly box launcher 14c shown in the image and Figure 15A and 15B The rolling mill-type box launcher 14d shown in the present disclosure is described therein. According to an advantageous embodiment of this disclosure, Figures 11A to 11C The belly box launcher 14c shown in the image and Figure 15A and 15BThe rolling mill-type box launchers 14d shown all feature a cage or safety bar 62 on the box or control console with a switch, preventing accidental button pressing or movement in the event of a launcher drop. At least a portion 62a of the safety bar is curved to provide a comfortable resting place for the operator's hands. The actuators on the box launchers 14c allow the operator to flexibly select the type of actuator and its position on the control console or box. The box-type control console may be equipped with a strap connected to a D-ring 64 of the wiring harness accessory to facilitate wearing the box console at the waist for easy and comfortable access and operation of the switches and other user inputs on the control console.

[0187] refer to Figures 11A to 11C 13 and 14, the box transmitter 14b is used in industrial environments and includes actuators on the user interface 30c to operate cranes or other mobile equipment. The battery-operated box transmitter 14c has various control inputs 32a, a twist-lock emergency stop button 32d, a start button 32c, a power on / off push-button switch 32i, a pairing switch 32j, a selector switch 32e, and a display 54. The box transmitter 14c wirelessly transmits the status of its buttons to a line-powered receiver, which can then control the electrical outputs associated with the operating crane or other mobile equipment 12. The box transmitter 14c is primarily designed to operate with an expandable receiver 16c and a digital receiver 16b, but can also operate with a standard receiver 16a. According to an advantageous embodiment of this disclosure, the box transmitter 14c is a customer-defined, configurable box.

[0188] refer to Figure 11B and 11C The following components of the 14c pylon launcher are shown and labeled:

[0189] 1. Toggle switch 32a;

[0190] 2. Instantaneous button 32b;

[0191] 3. Lock the two-position changeover switch 32f;

[0192] 4. Three-position toggle switch 32g;

[0193] 5. OLED display 54;

[0194] 6. Removable battery 42 in battery compartment 44;

[0195] 7. Side-mounted horn / start button 32c;

[0196] 8. Side-mounted selector button 32b;

[0197] 9. Emergency Stop (E-Stop) Twist Lock 32i;

[0198] 10. Key lock on / off switch

[0199] 11. Selector switch 32e;

[0200] 12. Potentiometer 32h;

[0201] 13. Side-mounted button 32j; and

[0202] 14. Reference number 14 wire harness accessory D-ring 64.

[0203] Figure 13 This is a block diagram of a box-type transmitter 14c according to an example embodiment. The box-type transmitter 14c has a processor 36 and a transceiver module 38. The transceiver module 38 has a built-in antenna 40 to prevent damage and provide sufficient support to ensure that the antenna does not detach from the transceiver during severe shock loads. For safety reasons, the box-type transmitter 14c is provided with a tilt switch 56 (e.g., two pendulum switches mounted inside the transmitter) to disable the transmitter 14c when it is tilted more than 30° from its normal forward / backward position or from side to side beyond an acceptable horizontal position. The box-type transmitter 14c is further provided with a dead switch 56, such as an SPST momentary button or actuator lever, which must be maintained to enable operation. The box-type transmitter 14c has a combination of Figure 14 The described battery monitor / power management circuit 52cd, which is deployed in the basic and standard transmitters 14a and 14b and is described above in conjunction with them. Figure 7 The battery monitor / power management circuit 52ab is essentially the same as described.

[0204] refer to Figure 12 and 13 The belly box launcher 14c has a set of standard controls for crane operation, such as:

[0205] ● A side-mounted start / horn button 32c is used to initiate the operation of the crane;

[0206] ● An emergency stop twist lock button 32d is used to terminate the operation of the crane;

[0207] ● Two side-mounted switches 32j are used to connect the box to the receiver;

[0208] ● A side-mounted, removable push-button switch 32i for supplying power to the enclosure; and

[0209] ● A display 54, which is used to communicate crane operations to the operator.

[0210] These buttons 32 are also used for self-diagnostics of the box transmitter 14c, such as button contacts being stuck or open. The display 54 provides the operator with detailed information such as (but not limited to) motion / speed indication, function activation, maintenance mode / diagnostics, overall battery status, pairing selection, currently paired device name, emergency stop activation, and tilt warning.

[0211] Continue to refer to Figure 12 and 13 The box-type transmitter 14c has up to four bidirectional spring-to-center lever switches or toggle switches 32a and up to 11 programmable lever status indicators, such as:

[0212] ● Vibration during transitions—The lever vibrates instantaneously when transitioning between speeds. The speed indicator is also displayed on the screen.

[0213] ● Vibration of speed—The lever vibrates at a predetermined rate at each defined speed. The higher the speed, the greater the amplitude of vibration. The speed is also indicated on the display.

[0214] ● None – The lever does not vibrate. Speed ​​indication is only on the display.

[0215] The box-type transmitter 14c can be configured with operators based on customer needs and applications, including the following switch configurator locations:

[0216] • Toggle switch position PSW1;

[0217] • Toggle switch position PSW2;

[0218] • Toggle switch position PSW3;

[0219] • Toggle switch position PSW4;

[0220] • Operator position A1;

[0221] • Operator position A2;

[0222] • Operator position B1;

[0223] • Operator position B2;

[0224] • Operator position B3;

[0225] • Operator position B4; and

[0226] • Operator position B5.

[0227] like Figure 13As shown, the box transmitter 14c can be operated using up to seven auxiliary switches, including (but not limited to) one or more push-button switches 32b, two-position toggle switches 32g, three-position toggle switches, two to ten configurable selector switches (up to one) 32e, and an analog switch (up to one) 32h. To implement different functions, the RCM interface software 28 transmits information to the processor 36 to correctly configure the signals. The four-position selector switches 32e and the analog switch 32h have dedicated inputs to the processor 36.

[0228] Figure 14 The illustration depicts the battery connection of an example box-type transmitter 14c. The box-type transmitter 14c is equipped with lithium batteries 42 (e.g., four lithium batteries), which can be connected via... Figure 11B The quick-connect battery compartment 44 is indicated at 6 locations for replacement. Each battery 42 has an EEPROM included in its assembly to track charging cycles, initial ampere-hour capacity, and current ampere-hour capacity. For example, one to three batteries 42 can be installed at a time. The batteries 42 externally charge the sub-carrier transmitter 14c. The sub-carrier transmitter 14c is powered on by turning the power button switch 32i to the ON position. At this time, the latch circuit 57 can connect the battery to other components in the sub-carrier transmitter 14c for operation. During power-off / overdue periods, the processor 36 can reset the latch 57 and disconnect the battery power from these other components in the sub-carrier transmitter 14c before the power supply capacitor 55a discharges, for proper power-off sequencing. Cyclic operation of the start switch 32c is required for further operation of the sub-carrier transmitter 14c.

[0229] The box-type transmitter 14c has a DIP switch 50 setting array, which can be accessed via the battery compartment 44 to configure unique settings for the transmitter 14c, such as (but not limited to) inactivity time selection, tilt switch activation, and dead activation. The box-type transmitter 14c is factory-configured with the correct number and type of switches required by the system according to customer requests. The lever / switch / button arrangement of the transmitter 14c is customized based on customer needs, and therefore, a customized configuration is loaded in each. The torsion lock emergency stop button 32d, start button 32c, on / off push-button switch 32i, NEXT button, and select momentary button 32b are not configurable. The RCM configuration generator 26 is used to generate customized switch configurations (e.g., using configuration file 26a). The configuration is then, for example, transferred to the transmitter 14c via USB through the RCM interface 28. The transmitter 14c and receiver 16 can be modified by the system user using the software of the RCM interface 28. The transmitter / receiver can access the configuration and logs using the software of the RCM interface 28.

[0230] The processor 36 in the box transmitter 14c analyzes and reports faults during normal operation and displays them on the display. To recover from a fault, the operator typically resolves the original fault. For some faults, the operator performs a system startup procedure to continue operation. For example, the processor 36 may detect communication loss (e.g., transmitter 14c is currently communicating with receiver 16 and has not received an acknowledgment message within 1 second). To restore radio communication, the start / horn button 32c is pressed. The processor 36 may also monitor invalid combinations of switches. For example, if an invalid combination of transmitter 14c switch 32 is detected, the box transmitter 14c may disable the faulty movement. When this error is cleared, normal operation of this movement can be restored. The processor 36 may also monitor the tilt switch 56, which should be held at <30 degrees to maintain function. When this error is cleared, normal operation can be restored. The processor 36 may also monitor the dead switch or lever 56, which should remain active for normal operation. In the event of a dead fault, the display 54 may indicate the fault, and all operations will cease. Once this error is cleared, normal operation will resume. Processor 36 also monitors for receiver failures (e.g., if transmitter 14c is currently communicating with the receiver and receiver 16 reports an error). Actions to mitigate such failures can be taken by the receiver, and further troubleshooting can be performed by individually evaluating the receiver.

[0231] Now refer to Figure 15A and 15B Sections 16 and 17 describe a mill-type box launcher 14d. The mill-type box launcher 14d is designed for use in mill environments and includes actuators for operating the crane 12. Because the mill-type box launcher 14d is used in mill environments, it is a more robust and scalable version of the industrial box launcher 14c. For example, the mill-type box launcher 14d has up to six bidirectional spring-to-center lever switches or toggle switches and up to 11 programmable lever status indicators, instead of those described in the references above. Figures 11A to 11C The four bidirectional spring-loaded center lever switches 32a provided in the box launcher 14c described in sections 12 to 14 are also included. Both the box launcher 14c and the mill-type box launcher 14d are highly configurable to suit a variety of crane topologies. Their design includes levers or joysticks 32a, 32c, toggle switches 32f, 32g, 32h, selector switch 32e, and buttons 32b, 32j, a locking emergency stop button 32d, a push-button switch 32i, LED indicators 34 for power, communication, and fault events, and a display 54 for descriptive information.

[0232] Basic, standard, box-type, and mill-type box-type transmitters 14a to 14d are advantageous because they are configured to have a transmitter maintenance mode, and for other reasons and advantages. Operations are initiated through this maintenance mode, such as (but not limited to) discovery, deletion, factory reset, general diagnostics, radio diagnostics, Rx log transmission, and Rx configuration transmission. Maintenance mode can be entered using user interface buttons and may vary depending on the transmitter type (i.e., basic, standard, box-type, or mill-type box-type transmitters 14a to 14d). Transmitter 14 maintains a selection list of receivers 16, which is built by performing discovery. Placing transmitter 14 in discovery mode adds receiver 16 to the selection list. Placing transmitter 14 in deletion mode removes receiver 16 from the selection list. Placing transmitter 14 in factory reset mode restores the transmitter to factory settings. To perform general diagnostics, transmitter 14 is placed in general diagnostic mode. Transmitter 14 can be placed in radio diagnostic mode to perform diagnostics. To retrieve receiver 16 logs, transmitter 14 is placed in receiver log transmission mode. Transmitter 14 typically has only available space to store a selected number of last transmitted logs. These logs can be transmitted to a PC via RCM software 26, 28. Transmitter 14 is placed in receiver configuration transmission mode to transmit the configuration to receiver 16. Before the receiver configuration transmission, the user needs to load the configuration (e.g., using configuration file 26a) onto transmitter 14 via RCM software 26, 28.

[0233] Different receivers 14 provided in the platform of the improved radio control system 10 will now be described according to exemplary embodiments of the present disclosure. Different example receivers 16 are: (Refer to...) Figures 18A to 18C and the standard receiver 16a described in 19, referenced Figures 18A to 18C And the digital receiver 16b described in 20, and reference 20 Figures 21A to 21C And the scalable receiver 16c described in 22. (See reference 22) Figures 23 to 27 The example expansion card 22 is described for use with the expandable receiver 16c. Figures 28 to 32 illustrate different example installations of the receiver 16.

[0234] The standard, digital, and scalable receivers 16a to 16c each share at least the following common characteristics:

[0235] ● Antenna 74 on receiver 16 is externally mounted to receiver housing and has an optional length extension;

[0236] ● Externally visible LED 90 for fault indication and internal diagnostic LED 88, and optionally a display for detailed information (not shown);

[0237] ● Supports self-diagnostic capabilities; and

[0238] ● A data log stored for receiver operation and failure occurrences, accessible via a computer interface or through a paired receiver.

[0239] The following is for reference. Figures 18A to 18C The standard receiver 16a described in section 19 is configured for commercial environments and includes the minimum features required to operate a crane, making it an affordable option for simpler or basic crane applications. The standard receiver 16a also includes relay outputs for controlling AC cranes. The relay outputs have pluggable connectors on a single PCBA for easy field replacement and are provided with color-coded and numbered tail cables to facilitate field installation. The standard receiver has a CANbus interface to further expand the number of control outputs. External cards can be mounted on snap-on rails or housings. External cards can be relay outputs for operating AC or DC cranes, analog outputs for controlling VFD cranes, or latched relay outputs for maintaining the current state during power outages. Each card has its own set of LEDs for fault indication.

[0240] The following is for reference. Figures 18A to 18C The digital receiver 16b described in section 20 is configured for use in commercial or industrial environments. The digital receiver has network connectivity to access system-level equipment (including network-enabled cranes) in a factory or other installation location. The digital receiver employs a CANbus architecture to extend control operation to external cards. External cards can be mounted on snap-on rails or housings. External cards can provide relay outputs for operating AC or DC cranes, analog outputs for controlling VFD cranes, or latched relay outputs for maintaining the current state during power outages. Each card has its own set of LEDs for fault indication.

[0241] The following is for reference. Figures 21A to 21CThe expandable receiver 16c described in section 22 is also configured for commercial or industrial environments and has network connectivity to access system-level equipment (including network-enabled cranes) in a factory or other installation location. The expandable receiver contains configurable output cards within its housing to control AC cranes. Pluggable card 22 can be a relay output for operating an AC crane or an analog output for controlling a VFD crane. The outputs on the configurable output cards have removable connectors for easy field replacement and are provided with color-coded and numbered tail cables to facilitate field installation. Each card has its own set of LEDs for fault indication. For added scalability, external cards can be installed in the system via a CANbus interface. External cards can be mounted on a snap-on rail or housing. External cards can be relay outputs for operating an AC crane, analog outputs for controlling a VFD crane, or latched relay outputs for maintaining the current state during power outages. Each card has its own set of LEDs for fault indication.

[0242] Receiver 16 (e.g., standard receiver 16a, digital receiver 16b, or expandable receiver 16c) can generate the following responses to the following transmitter requests: discovery request (e.g., the receiver can identify itself by sending a message containing its unique address and other relevant information); remote operation initiation request (e.g., the receiver can enable and verify the power of its output and take action on received motion, speed, and assistive functions based on its configuration settings); operation log transmission request (e.g., the receiver can send a history of control changes); and configuration transmission request (e.g., the receiver can accept and store a set of configuration settings). For wireless remote control operation of the equipment, the transmitter can send the status of all levers / switches / inputs to the paired receiver at intervals of <=300ms.

[0243] Receiver 16 (e.g., standard receiver 16a, digital receiver 16c, or expandable receiver 16c) updates its output state based on changes in input. For data logging, an improved radio control system records the history of receiver control changes (e.g., via receiver or transmitter). Logs can be transmitted and viewed using the RCM interface. For power-off, the receiver typically has no power-saving mode and is turned on when power is applied and off when power is disconnected.

[0244] Receiver 16 (e.g., standard receiver 16a, digital receiver 16b, or expandable receiver 16c) also performs fault detection / safety monitoring. For fault detection / safety monitoring, the improved radio control system analyzes and reports faults (e.g., at the receiver or transmitter) during normal operation and indicates the fault by illuminating a fault LED and disabling power to its output. To recover from a fault, the operator typically must resolve the original fault. For some faults, a system startup procedure on the transmitter is required to continue operation. For a mainline contactor fault, receiver 16 monitors the output status of the mainline contactor, and if the assumed output status differs from the actual status, this will result in a fault, and the output power will be disconnected. For communication loss (e.g., if the receiver is currently communicating with transmitter 14 and does not receive an acknowledgment message within 1 second), the output power will be disconnected. To resume operation, the operator can rebuild communication between transmitter 14 and receiver 14 by pressing the start / horn button 32c on transmitter 14. In the event of a CANbus communication failure (e.g., if receiver 16 does not receive a message from the configured CANbus slave device within 1 second, then a failure occurs), the associated motion controlled on this CANbus slave device will become inoperable, but other motions can continue to operate. Digital receiver 16b can also be configured to monitor Ethernet 110 communication failures and / or MODBus 112 communication failures.

[0245] Figure 18A , 18B 18C and 18C are respectively the front view, side view and rear view of the example housing of the standard receiver 16a or the digital receiver 16b according to the example embodiments. Figure 19 This is a block diagram of a standard receiver 16a according to an example embodiment. (See reference) Figures 18A to 18C And 19, the standard receiver 16a is primarily configured to operate in conjunction with the basic transmitter 14a (e.g., in combination with...). Figures 4A to 7 (Description), but it can also be activated at only two speeds with the standard transmitter 14b (e.g., in combination). Figures 8A to 10 and Figure 7 It operates together with the described) and with the abdominal box launcher 14c (e.g., in combination with) Figures 11A to 14 (as described) or mill-type box launcher 14d (e.g., in combination with) Figures 15A to 17 (As described) They operate together, but with limited functionality. For example, the standard receiver 14a can be implemented using several PCBAs, such as Figure 19 The receiver motherboard shown includes a processor 36, a transceiver module 72 (which has an external antenna connector for mounting an external antenna 74 to increase the receiving / transmitting range), and a power supply module. Furthermore, the standard receiver 16a has at least the following characteristics:

[0246] • Configurable power supply 78;

[0247] • Main contactor interface 80;

[0248] • 12 Type A outputs, 82;

[0249] • Two C-type outputs, each 84;

[0250] • External CANbus interface 86 for further expansion (e.g., power interface 86a and communication interface 86b);

[0251] • Internal diagnostic LED 88;

[0252] • 90 LEDs mounted in the housing;

[0253] • Buzzer 92 mounted on the casing;

[0254] • External speaker connection 94; and

[0255] • Cable 96 (e.g., Figure 18A The tail cable 96 shown in 8C can be, for example, 4 feet.

[0256] For example, the standard receiver 16a can be configured by the power module 76 to operate on general-purpose AC (84-265VAC) power or low-voltage 24Vac / Vdc power. The standard receiver 16a initiates operation via a handshake between the mainline contactor (MLC) and its start function. The operator initiates the start operation from the transmitter 14, which uses the mainline contactor interface, indicated integrally at 80, to connect an external start relay input to the mainline contactor via a start relay (e.g., using a start-forced-guided relay). During initial setup, the standard receiver 16a monitors the start-forced-guided mainline contactor relay to verify that the relay is not faulty or that no other fault has occurred. If the receiver 16a fails, the receiver can interrupt the start operation. In the absence of a fault, the receiver 16a then enables its mainline contactor relay for crane operation. The internal mainline contactor relay is triggered via an output from the processor 36 and a watchdog timer. If the processor 36 output is cleared due to an emergency stop or system failure, or if the watchdog function is cleared due to processor failure, then the main contactor interface circuit indicated at 80 is disabled, and power to all other outputs is disabled, rendering receiver 16a inactive. Receiver 16a further includes one or more field-replaceable fuses (e.g., 98a and 98b) that protect the power module 76 input, main contactor interface 80, and selected motion outputs 82, 84.

[0257] Continue to refer to Figures 18A to 18CAnd 19, the standard receiver 16a is provided with a housing-mounted indicator 90 (e.g., an LED). For example, the standard receiver 16a has a feature for... Figure 18A The externally mounted LED 90 shown is connected for user visual notification, such as (but not limited to):

[0258] ● The front panel-mounted power / heartbeat LED 90a is used to indicate receiver power and processor operation;

[0259] ● The front panel-mounted LED 90b is used to indicate the pairing mode / wireless communication to the receiver;

[0260] ● The front panel-mounted LED 90c is used to indicate fault conditions.

[0261] The standard receiver 16a also features an optional housing-mounted buzzer 92 for audible notifications to the user.

[0262] Continue to refer to Figures 18A to 18C And 19, the external CANbus 86 provided to the standard receiver 16a allows for the addition of output expansion. Address definitions are defined on the external CANbus device (e.g., card 22) via selector switch 116 on the external CANbus device. If the hardware configuration is out of sync with the software configuration of the RCM interface 28, a fault will be detected, and the receiver will become inoperable. The standard receiver 16a is configured to operate with the assemblies described below. The digital receiver 16b is configured to operate with the following assemblies described below:

[0263] ● ECFA - Type A Relay Output Expansion Card;

[0264] ● ECFC - Type C relay output expansion card;

[0265] ● ECDR - DC Crane Relay Output Expansion Card;

[0266] ● ECAI - Analog Interface Expansion Card; and

[0267] ● ECLO - Latch Output Expansion Card.

[0268] Continue to refer to Figures 18A to 18C And 19, the standard receiver 16a is equipped with 14 relay outputs. The functions of the relays may include (but are not limited to):

[0269] ● 3 bidirectional, two-speed motion units (12 relay outputs) 82; and

[0270] ● 2 configurable relays (2 separate dedicated relay outputs) 84.

[0271] For three bidirectional, two-speed movements, each movement pair shares a fuse and is associated with a movement / speed button (e.g., 32a) on transmitter 14. For two configurable relays 84, there is no fuse for the output. Normally closed and normally open outputs are provided and are associated with a fourth speed / auxiliary button (e.g., 32b) on transmitter 14 (e.g., bidirectional single-speed movement and two general-purpose output contacts). The standard receiver further includes an array of DIP switches 104 that configure unique settings for the receiver for features such as: DIP switch control or RCM configuration, relay outputs for speed operation, presence of an external buzzer 92, channel selection, and system configuration. For example, three positions of the DIP switches 104 can be used to configure the relay output speed to one of the following: single speed; dual-speed, shared speed relay; dual-speed open / close speed; dual-speed close / close speed; dual-speed slow / fast type A; or dual-speed slow / fast type B. Features other than these require operator configuration using RCM interface software.

[0272] The standard receiver 16a can access the data log via software through the RCM interface 28 via either of two paths: the USB connection 108 on the receiver 16a, or remote access via a link established with the transmitter 14. The data log may contain the following information: receiver operation, fault occurrence, operation time, and pairing configuration.

[0273] Figure 20 This is a block diagram of a digital receiver 16b according to an example embodiment. (See reference) Figures 18A to 18C And 20, the digital receiver 16b has a CANbus 86, which provides access to the control card for optional digital and analog outputs based on the crane's requirements. Ethernet port 110 can be used to interface with a PLC to operate the crane 12 via a network, or to be directly connected to the crane. The digital receiver 16b is primarily configured to work with the standard transmitter 14b (e.g., in conjunction with...). Figures 8A to 10 and Figure 7 It operates together with the described) and with the abdominal box launcher 14c (e.g., in combination with) Figures 11A to 14 (as described) or mill-type box launcher 14d (e.g., in combination with) Figures 15A to 17 The digital receiver 16b can also operate with the basic transmitter 14a (e.g., in combination with...). Figures 4A to 7 (As described), but with limited operation. The digital receiver 16b can be implemented, for example, with several PCBAs, such as Figure 20 The digital receiver carrier board shown includes a processor 36, a transceiver module 72 (with an external antenna 74 connector for external antenna mounting to increase the receiving / transmitting range), and a power supply module 76. Furthermore, the digital receiver 16b has at least the following characteristics:

[0274] • Configurable power supply 78;

[0275] • Main contactor interface 80;

[0276] • External CANbus interface 86 for further expansion;

[0277] • External Ethernet interface 110 for network connectivity;

[0278] • Internal diagnostic LED 88;

[0279] • 90 LEDs mounted in the housing;

[0280] • The housing mounts a buzzer 92; and

[0281] • External speaker connection 94.

[0282] For example, digital receiver 16b can be configured by power module 76 to operate with a 24Vdc power supply. Alternatively, the digital receiver can operate with a universal AC (84-265VAC) power supply. Digital receiver 16b initiates operation via a handshake between the mainline contactor (MLC) and its start function. The operator initiates the start operation from transmitter 14, which uses the mainline contactor interface, indicated integrally by 80, to connect an external start relay input to the mainline contactor via a start relay (e.g., using a start-forced-guided relay). During initial setup, digital receiver 16b monitors the start-forced-guided mainline contactor relay to verify that the relay is not faulty or that no other fault has occurred. If receiver 16b fails, the receiver can interrupt the start operation. In the absence of a fault, receiver 16b then enables its mainline contactor relay for crane operation. The internal mainline contactor relay is triggered via an output from processor 36 and a watchdog timer. If the processor 36 output is cleared due to an emergency stop or system failure, or if the watchdog function is cleared due to processor failure, the main contactor interface circuit indicated at 80 is disabled, and power to all other outputs is disabled, rendering receiver 16b inactive. The digital receiver carrier further includes one or more field-replaceable fuses (e.g., 98a, 98b) that protect the power module 76 input and the main contactor interface 80 located on the digital receiver carrier.

[0283] Continue to refer to Figures 18A to 18C And 20, the digital receiver 16b is provided with a housing-mounted indicator 90 (e.g., an LED). For example, the digital receiver has a connection for an externally mounted LED for user visual notification, such as (but not limited to):

[0284] ● The front panel-mounted power / heartbeat LED 90a is used to indicate receiver power and processor operation;

[0285] ● The front panel-mounted LED 90b is used to indicate the pairing mode / wireless communication to the receiver;

[0286] ● The fault LED 90c mounted on the front panel is used to indicate the fault status.

[0287] The digital receiver 16b also features an optional housing-mounted buzzer 92 for audible notifications to the user.

[0288] Continue to refer to Figures 18A to 18C And 20, the external CANbus 86 provided to the digital receiver 16b allows for the addition of output expansion. Address definitions are defined on the external CANbus device (e.g., card 22) via selector switch 116 on the external CANbus device. If the hardware configuration is out of sync with the software configuration of the RCM interface 28, a fault will be detected, and the receiver 16b will become inoperable. The digital receiver 16b is configured to operate with the following assemblies described below:

[0289] ● ECFA - Figure 24 The Type A relay output expansion card 22b shown in the image;

[0290] ● ECFC - Figure 25 The C-type relay output expansion card 22c shown in the image;

[0291] ● ECDR - Figure 23 The DC crane relay output expansion card 22a shown in the image;

[0292] ● ECAI - Figure 27 The analog interface expansion card 22e shown in the image; and

[0293] ● ECLO - Figure 26 The latch output expansion card 22d shown in the image.

[0294] As stated above, the digital receiver 16b further has an Ethernet port 110 for interfacing with a network via a PLC to operate the crane or for direct connection to the crane.

[0295] The digital receiver 16b further includes an array of DIP switches 104 that configure unique settings for the receiver for features such as: DIP switch control or RCM configuration, relay output for speed operation, presence of an external buzzer, channel selection, and system configuration.

[0296] The digital receiver 16b can access the data log via software through the RCM interface 28 via either of two paths: the USB connection 108 located on the receiver, or remote access via a link established with the transmitter. The data log may contain information such as receiver operation, fault occurrence, operation time, and pairing configuration. The debug connection 106 and the USB connection 108 can alternatively be implemented using a single common connection.

[0297] Figure 21A , 21B 21C and 21C are respectively the front view, side view and rear view of the example housing of the expandable receiver 16c according to the example embodiment. Figure 22 This is a block diagram of a scalable receiver 16c according to an example embodiment. (See reference) Figures 21A to 21C And 22, the expandable receiver 16c has a base plate with standard operation and includes expandable digital and analog outputs based on the requirements of crane 12 (e.g., via card 22 in a card slot, or overall mounting via a snap-on rail or housing indicated by 120). The expandable receiver 16c is primarily configured to work with the standard transmitter 14b (e.g., in conjunction with...). Figures 8A to 10 and Figure 7 It operates together with the described) and with the abdominal box launcher 14c (e.g., in combination with) Figures 11A to 14 (as described) or mill-type box launcher 14d (e.g., in combination with) Figures 15A to 17 The expandable receiver 16c can also operate with the basic transmitter 14a (e.g., in combination with...). Figures 4A to 7 (As described) They operate together, but with limited operation. For example, the scalable receiver 16c can be implemented with several PCBAs, such as Figure 22 The receiver carrier board shown includes a processor 36, a transceiver module 72 (with an external antenna connector for mounting an external antenna 74 to increase the receiving / transmitting range), a power module 76, a Type A relay output slot, a Type C relay output slot, and an analog interface slot, indicated, for example, by 120. Furthermore, the expandable receiver 16c has at least the following features:

[0298] • Configurable power supply 78;

[0299] • Up to 48 configurable control outputs, indicated in 120;

[0300] • Main contactor interface, indicated by 80 throughout;

[0301] • External CANbus interface 86 for further expansion;

[0302] • Internal diagnostic LED 88;

[0303] • 90 LEDs mounted in the housing;

[0304] • Buzzer 92 mounted on the casing;

[0305] • External buzzer connection 94; and

[0306] • Figures 21A to 21C The cable 96 shown in the image (e.g., 3', 10', or 25' extension tail cable).

[0307] For example, the scalable receiver 16c can be configured by the power module 76 to operate in the location Figure 22 The receiver carrier shown in the diagram is powered by a general-purpose AC (84-265VAC) or low-voltage 24Vac / Vdc power supply. The expandable receiver 16c begins operation via a handshake between the mainline contactor (MLC) and its start function, through the mainline contactor interface indicated by 80 and as described above in conjunction with receiver 16b. The operator initiates the start operation from transmitter 14, which connects an external start relay input to the mainline contactor via a start relay. During initial setup, the expandable receiver 16c monitors the forced-direction mainline contactor relay to verify that the relay is not faulty or that no other fault has occurred. If receiver 16c fails, the receiver can interrupt the start operation. In the absence of a fault, receiver 16c then enables its mainline contactor relay for crane operation. The internal mainline relay is triggered via an output from processor 36 and a watchdog timer. If the processor 36 output is cleared due to an emergency stop condition or system fault, or if the watchdog function is cleared due to processor failure, the mainline contactor interface circuitry is disabled, and power to all other outputs is disabled, rendering receiver 16c inactive. Figure 22 The expandable receiver carrier shown further includes one or more field-replaceable fuses (98a, 98b) that protect the power module input, and a mainline contactor interface 80 located on the expandable receiver carrier.

[0308] Continue to refer to Figures 21A to 21C And 22, the expandable receiver 16c is provided with a housing-mounted indicator 90 (e.g., an LED). For example, the expandable receiver 16c has a connection for externally mounted LED 90 for user visual notification, such as (but not limited to):

[0309] ● At least one front-panel mounted power / heartbeat LED 90a, which is used to indicate receiver power and processor operation;

[0310] ● The front panel-mounted LED 90b is used to indicate the pairing mode / wireless communication to the receiver;

[0311] ● The fault LED 90c, mounted on the bottom housing, is used to indicate fault conditions.

[0312] The expandable receiver 16c also features an optional housing-mounted buzzer 92 for audible notifications to the user.

[0313] Continue to refer to Figures 21A to 21C And 22, the receiver carrier card interface allows the receiver 16c to be configured with different types and numbers of internal expansion cards. A locally isolated CANbus interface provides communication between the receiver carrier and the expansion cards. The expandable receiver is configured to operate with the following card slot expansions.

[0314] ● CSFA - Type A relay output card slot;

[0315] ● CSFC - Type C Relay Output Slot

[0316] ● CSAI - Analog Interface Card Slot;

[0317] Each card slot has a defined address from 0 to 5 associated with its location. If the hardware configuration is out of sync with the RCM software configuration, a fault will be detected, and the receiver, or at least the affected card, will become inoperable. Additionally, an external CANbus 86 provided to the expandable receiver allows for the addition of output expansions. The external CANbus operates on the same internal CANbus that communicates with the expansion card. Address definitions are defined on the external CANbus device via selector switches on the external CANbus device. External CANbus addresses cannot be 0 to 5, otherwise they will conflict with the internal CANbus slot. The expandable receiver is configured to operate with the following external assemblies described below:

[0318] ● ECFA - Type A Relay Output Expansion Card;

[0319] ● ECFC - Type C relay output expansion card;

[0320] ● ECDR - DC Crane Relay Output Expansion Card;

[0321] ● ECAI - Analog Interface Expansion Card; and

[0322] ● ECLO - Latch Output Expansion Card.

[0323] If the hardware configuration and the RCM interface software configuration are out of sync, a fault will be detected, and the receiver will become inoperable.

[0324] The expandable receiver 16c further includes an array of DIP switches 104 that configure unique settings for features such as DIP switch control or RCM configuration, relay output for speed operation, presence of an external buzzer, channel selection, and system configuration.

[0325] The expandable receiver 16c can access the data log via software through the RCM interface 28 via either of two paths: the USB connection 108 set on the receiver, or remote access via a link established with the transmitter 14. The data log may contain information such as receiver operation, failure occurrence, operation time, and pairing configuration. The debug connection 106 and the USB connection 108 can alternatively be implemented using a single common connection.

[0326] Now refer to Figures 23 to 27 Examples of different expansion cards 22 in the platform of the improved radio control system 10 are described. According to an example embodiment of this disclosure, individual expansion cards can be inserted into the CANbus 86 of the expandable receiver 16c (e.g., in conjunction with the above). Figures 21A to 22 (As described). Different expansion cards 22, each board having various outputs, include the main receiver 16c board in the expandable receiver 16c (e.g., referenced above). Figure 22 The receiver carrier board (with processor 36) can control it. Each expansion card 22 has an onboard processor 36, which can communicate in reverse with the master processor 36 in the expandable receiver 16c via CANbus 86. Each expansion card 22 has a unique address set by an onboard hexadecimal switch 116. This address (e.g., 0x0 to 0xF) is set accordingly in the configuration of the receiver 16c. The processor 36 of the expansion card 22 is configured to operate as a CANbus slave device, while the master processor 36 in the expandable receiver 16c operates as a CANbus master device. The outputs of the expansion card 22 will be set or cleared in response to commands from the wireless transmitter 14. An LED status indicator 122 associated with each expansion card 22 can report faults, CANbus communication, and power status, as described below. Figures 23 to 27 The example expansion card 22 shown in the illustration is described. The default configuration in receiver 16c can be used to assign the appropriate output on expansion card 22 to incoming wireless commands from transmitter 14. If a configuration beyond the default configuration is required, RCM configuration generator 26 can also be used. Configuration file 26a is transmitted to receiver 16c via RCM interface 28 software.

[0327] Further details regarding the following text Figures 23 to 27The described expansion card 22 and receiver 16c perform a self-diagnostic test after power is applied to the system for startup. Receiver 16c then loads its most recently stored configuration (e.g., via configuration file 26a). The self-diagnostic test running on receiver 16c confirms CANbus communication 86 with the configured expansion card 22. During this time, a fault LED 90c will pulse for 5 seconds. At the end of the 5 seconds, if any fault is detected, it will remain lit; otherwise, it will clear. After a successful self-diagnostic test, receiver 16c awaits a request from transmitter 14. Regarding fault detection / safety monitoring, transmitter 16 / receiver 16 analyzes and reports faults during normal operation and indicates the fault by illuminating the corresponding fault LED. To recover from a fault, the operator must typically resolve the original fault. If expansion card 22 does not receive a message from the CANbus master (e.g., receiver 16c) within 1 second, a CANbus communication fault is declared. In response to such a fault, the associated motion output controlled on this CANbus slave device 22 becomes inoperable.

[0328] Further details regarding the following text Figures 23 to 27 The different expansion cards 22 described are each configured to operate with a 24Vdc power supply. Each expansion card has a connection for internal diagnostic LEDs 122 for user visual notifications, such as (but not limited to):

[0329] ● A power / heartbeat LED, used to indicate receiver power and processor operation;

[0330] The constantly lit indicator light shows that the receiver is powered on.

[0331] o Flashing indicates that the receiver is powered on and is in operation;

[0332] ● A tri-color LED used to indicate CANbus communication;

[0333] o Green indicates CANbus operation;

[0334] o Red indicator shows CANbus failure; and

[0335] ● A red fault LED is used to indicate the fault status.

[0336] To enable fail-safe operation, the relay power supply is triggered via the processor output and the watchdog timer. If the processor output is cleared due to an emergency stop or system failure, or if the watchdog timer is cleared due to processor failure, the relay power supply is disabled, rendering the output inactive.

[0337] Further details regarding the following text Figures 23 to 26The different expansion cards described each have redundant CANbus and power interfaces 86a and 86b to enable "daisy-chain" operation of multiple devices on CANbus 86. Each expansion card 22 also has a hexadecimal switch 116 for configuring the CANbus address between (0 and 15(F)), as described above. On the other hand, regarding the following combination Figure 27 The expansion card 22e is described; that is, the expansion card 22e with analog output is connected to the reference via its expansion card interface (e.g., the analog interface card slot described above for controlling the analog output of a VFD crane). Figures 21A to 22 The aforementioned receiver carrier board of the scalable receiver 16c is described.

[0338] Figure 23 This is a block diagram of a DC relay output expansion card (ECDR) 22a, which can be deployed with an expandable receiver 16c according to an example embodiment. ECDR 22a includes a CANbus interface indicated at 86 and four Type A output interfaces indicated at 124, which use local power to enable the high-voltage / current relays required to operate a DC crane. ECDR 22a is designed to operate with the example receiver product described above in an improved radio control system 10 platform that incorporates an external CANbus interface 86. In addition to mounting in the slot indicated overall at 120, ECDR 22a can also be mounted in a panel or in a snap-on rail. ECDR 22a has the following features:

[0339] ● The DC relay has four Type A contact interfaces 124;

[0340] ● For adding an extended redundant CANbus interface 86;

[0341] ● For adding extended redundant power supply connections 126;

[0342] ● Internal diagnostic LED 122; and

[0343] ● Configurable hexadecimal CANbus address selected via switch 116.

[0344] For example, the ECDR has four voltage contact output interfaces, which are designed to enable the CAD32BD contactor in response to the voltage and current requirements of DC crane control signals.

[0345] Figure 24This is a block diagram of a Type A Output Expansion Card (ECFA) 22b, which can be deployed with an expandable receiver 16c according to an example embodiment. The ECFA 22b includes a CANbus interface 86 and eight Type A relay outputs (e.g., two sets of four Type A relays sharing a common fuse), generally indicated by 124. The ECFA 22b is designed to work with the expandable receiver 16c (e.g., as described above). Figures 21A to 22 As described above) and digital receiver 16b (e.g., in conjunction with the above) Figures 18A to 18C Together with (as described in section 20), ECFA 22b has the following characteristics:

[0346] ● 8 Type A outputs, 124;

[0347] ● For adding an extended redundant CANbus interface 86;

[0348] ● LED fault indicator 122; and

[0349] ● Configurable hexadecimal CANbus address selected via switch 116.

[0350] ECFA includes field-replaceable fuses, protecting each of the 124 sets of fuses in the protection output.

[0351] Figure 25 This is a block diagram of a Type-C Output Expansion Card (ECFC) 22c, which can be deployed with an expandable receiver 16c according to an example embodiment. The ECFC 22c includes a CANbus interface 86 and four Type-C relay outputs (e.g., four individual fuse-less Type-C output relays providing common, normally open, and normally closed contacts for field connections), collectively indicated by 124. The ECFC 22c is designed to work with the expandable receiver 16c (e.g., in conjunction with the above). Figures 21A to 22 As described above) and digital receiver 16b (e.g., in conjunction with the above) Figures 18A to 18C And (as described in 20) operate together. ECFC 22c has the following characteristics:

[0352] ● 4 C-type outputs 124;

[0353] ● For adding an extended redundant CANbus interface 86;

[0354] ● LED fault indicator 122; and

[0355] ● Configurable hexadecimal CANbus address selected via switch 116.

[0356] ECFA includes field-replaceable fuses that protect each set of fuses in the 124 indicated outputs.

[0357] Figure 26This is a block diagram of a latched output expansion card (ECLO) 22d, which can be deployed with an expandable receiver 16c according to an example embodiment. The ECLO 16d includes a CANbus interface 86 and two latched output interfaces indicated at 124. For example, the ECLO 22d has two latched output interfaces designed to enable the LA6DK / CAD32BD contactor combination. A pulse between contactor coil terminals A1 & A2 causes the contactor to close. A pulse between latched coil terminals E1 & E2 opens the contactor. The pulse duration is a minimum of 250 ms and a maximum of 10 seconds. Terminals A and E should not be energized simultaneously. The ECLO 22d is designed to operate with receiver products that incorporate an external CANbus interface. In addition to mounting in a slot indicated at 120, the ECLO 22d can be installed in a housing or in a snap-fit ​​rail. The ECLO 22d has the following features:

[0358] ● Two latch output interfaces 124;

[0359] ● For adding an extended redundant CANbus interface 86;

[0360] ● For adding extended redundant power supply connections 126;

[0361] ● Internal diagnostic LED 122;

[0362] ● Optional housing for mounting 128 LEDs; and

[0363] ● Configurable hexadecimal CANbus address selected via switch 116.

[0364] The ECLO 22d features an internal LED 122 for indicating power supply and communication failures with the receiver interface, as well as a diagnostic LED 128 mounted on the casing of each expansion card, as described above.

[0365] Figure 27 This is a block diagram of an expansion card (ECAI) 22e with analog interface outputs that can be deployed with an expandable receiver 16c according to an example embodiment. The ECAI 22e provides four Type C relay outputs (e.g., four individual fuse-less Type C output relays that provide common, normally open, and normally closed contacts for field connections), indicated by 124 overall.

[0366] Figure 28A and 28B These are diagrams illustrating corresponding example embodiments of expandable receivers with different expansion cards or auxiliary housings having outputs in a remote crane control system according to example embodiments. For example, Figure 28AAn example of an exploratory receiver cabinet, which is described according to an illustrative embodiment, includes expansion cards that provide different types of output.

[0367] Receiver cabinet 140 includes a network interface 142 and a local CANbus interface 86. Expansion card 22 is interfaced to receiver cabinet 140 via the local CANbus interface. For example, output 124 has a pluggable connector on a single PCBA for easy field replacement and includes color-coded and numbered tail wires to facilitate field installation. Network interface 142 allows receiver 16, indicated at 136 in cabinet 140, to be directly connected to other system components, including a PLC for crane operation. For example, receiver 136 includes a transceiver module 72, processor 36, buzzer 92, computer interface 108, and indicator 90 as described above, as well as a display 138 for indicating status.

[0368] Figure 28B An example of an expandable receiver housing 146, having an interface to a separate auxiliary expansion card housing 148, is depicted according to another illustrative embodiment. For example, Figure 28B The design shown includes one or more housings 148 containing outputs 124 for controlling the AC crane 12. Receiver housing 146 includes a network interface 142 and a local CANbus interface 86 for up to six internal expansion cards, for a total of up to 48 outputs. Auxiliary housings 148 are also connected to the receiver housing via the local CANbus interface 86, and each auxiliary housing has up to 16 outputs, depending on the type of output supported by the particular auxiliary housing 148 in a manner similar to the different types of expansion cards 22 described above. For example, auxiliary housing outputs 124 can be connected using pluggable connectors on a single PCBA for easy field replacement and include color-coded and numbered tail wires to facilitate field installation.

[0369] Figures 29 to 31 These are three different implementations of an improved radio control system 10 according to exemplary embodiments of the present disclosure. Figure 29 The overall topology of the remote control relay cabinet is illustrated by 10d, wherein the receiver relay cabinet 150 includes a receiver 16 hardwired to an intermediate relay indicated by 152 and a changeover switch 154 connected to a control unit of the existing device 12. Figure 30 Describe the topology of the remote control VFD cabinet, wherein the receiver cabinet includes a receiver 16 that is hardwired to the variable frequency drive in the existing device 12 via a changeover switch XX. Figure 31 This describes a remote control customer connection topology, in which receiver 16 is supplied with a cable harness having a multi-core cable 156 for direct connection to the customer so that they can install it to control mobile equipment (e.g., a crane).

[0370] refer to Figures 29 to 31 The transfer switch in the relay cabinet may include a large drum switch. The receiver logic of the transfer switch relay may be, for example:

[0371] ● When the manual selector switch is set to radio, it allows the selector relay to energize the selected radio operation; and

[0372] ● The changeover relay should only be de-energized when all directional inputs are centered. This will keep the cabinet powered and active until all joysticks are centered. This is because the relay can carry 16 A, but can only disconnect 1.5 A at 250VDC.

[0373] Various embodiments of the receiver in the improved radio control system described herein can be configured to provide CANbus, Modbus RTU (RS-485, 2-wire), and Modbus TCP / IP (Ethernet) fieldbus protocols. These are bus protocols, but packet collisions can be avoided by synchronously sending packets at defined time intervals. Synchronized packet transmission can be used to identify communication loss.

[0374] The transmitter 14 and receiver 16 for the improved radio control system 10 described herein based on exemplary embodiments offer several advantages, such as novel switches, design and user-friendly interface, and more speed and control options due to configurable switches.

[0375] Also referenced is made to a co-pending application entitled “Programmable Haptic Feedback Fingertip Paddle Switch,” the entire contents of which are incorporated herein by reference, which discloses a novel 11-position analog switch capable of operation in harsh environments (HA). This novel programmable haptic feedback fingertip paddle switch (e.g., switch 32a shown and described herein with respect to box emitter 14c and mill box emitter 14d) is configured to provide a customer or emitter operator with the ability to feel haptic feedback at the switch position or condition, even in industrial environments where the operator wears protective gloves. This novel programmable haptic feedback fingertip paddle switch 32a offers numerous advantages over conventional joysticks, which cannot withstand harsh environments or provide the desired tactile feedback.

[0376] The transmitter 14 and receiver 16 of the exemplary embodiments described herein are configured to withstand harsh and dirty environments. The transmitter 14 and receiver 16 of the exemplary embodiments described herein are also configured to withstand repeated drops by customers or operators.

[0377] This document describes one or more of the various transmitters 14 and receivers 16 described in connection with the product platform from which the improved radio control system 10 can be designed and implemented, configured to meet safety standards and certifications. The various transmitters 14 and receivers 16 described in connection with the product platform from which the improved radio control system 10 can be designed and implemented are also configured to meet Underwriters Laboratories, Inc. (UL) standards, such as (but not limited to) UL 1638 for visual signaling facilities and UL 2017 for general signaling devices and systems.

[0378] The various transmitters 14 described herein possess beneficial safety features, such as safety circuitry (e.g., tilt sensor 56 and associated cut-off switch), and a cage 62 on the box and mill-type box transmitters 14c, 14d, which prevents accidental button presses or movement or other switch operations in the event of a transmitter drop. The cage or safety bar 62 is also ergonomically curved to provide comfort for the operator when placing their hand on the safety bar. Digital and standard transmitters 14a, 14b with handheld shape factors are advantageously configured to fit the operator's palm, allowing the operator to hold the transmitter in their hand while strapped to their wrist or waist and operate the transmitter buttons with the fingers of said hand. The example transmitters 14 described herein incorporate additional ergonomic mechanical protection mechanisms to prevent accidental operation due to impact.

[0379] The transmitter's power requirements are advantageously managed to provide crane status, battery status, and connection status on its display. The transmitter display may also allow operator input (e.g., on a GUI display 54). Transmitter 14 can operate on battery power, and the battery across the product platform from which the improved radio control system can be designed and implemented is common. For example, transmitter 14 has a single-point battery (e.g., lithium battery 42, which can be replaced via a quick-connect battery compartment 44 in the transmitter housing or casing). For example, transmitters 14c, 14d with a box-shaped form factor can use two 18650 or custom lithium battery packs, while transmitters with a handheld form factor use a single 18650 lithium battery or a rechargeable battery pack. This single-point battery design in the platform of the improved radio control system 10 disclosed herein is superior to conventional radio control system product lines from various manufacturers that use different types of batteries (e.g., C and A batteries for shape factor transmitters and receivers) or proprietary batteries that are not common to these manufacturers' product lines, making it more complex, expensive, and inconvenient for customers to use the product line and for manufacturers to maintain the product line inventory. The lithium-ion battery 42 used in transmitter 14 can be charged on transmitter 14 or via a separate charger. Figure 32A , 32B32C is a side view and a front perspective view of an example handheld battery charger 158 constructed according to an example embodiment. Figure 32B The display shows a handheld battery charger 158 without battery charging, and Figure 32C The handheld battery charger 158, which includes a 42-cell battery, is on display. Figure 33 Another example of a battery charger 160 constructed according to an exemplary embodiment is described. The battery charger 160 is configured to charge multiple batteries for use in a box-type transmitter 14c or a mill-type box-type transmitter 14d. The rechargeable batteries have extended battery capacity to provide longer operating time.

[0380] The transmitter 14 and receiver 16 of the improved radio control system 10 described herein, according to exemplary embodiments, are advantageously equipped with USB / C connectors (e.g., 46, 108) for transmitting switch configurations to the transmitter 14, accessing data logs, and updating software. The USB / C connector is more universal and therefore easier to operate than the proprietary joysticks typically required by existing radio control systems (i.e., especially in the field). The described transmitter 14 and receiver 16 perform operation and fault logging for diagnostics and incident forensic analysis, which is highly beneficial for users to maintain optimal operation of their custom-designed improved radio control systems. The receiver described herein, according to exemplary embodiments, has external control input and output interfaces (i.e., CANbus, Profibus, and / or Modbus) for factory integration and automation. The convenient and versatile configurability of the transmitter and receiver described herein, according to exemplary embodiments, facilitates customization by system operators for various radio control applications across a wide range of mobile equipment. Therefore, the improved radio control system achieves significant advantages over existing systems from large OEMs, which primarily focus on building custom product lines for large customers and cannot easily configure the same equipment for use in radio control systems for other customers and applications.

[0381] The ease of use and versatility of the transmitter 14 and receiver 16 described herein, based on exemplary embodiments, also facilitates product development and product line or platform expansion for the improved radio control system described herein by system developers. For example, cross-platform firmware simplifies product line or platform expansion of the improved radio control system. Because the processors in transmitter 14, receiver 16, and expansion card 22 interface with the hardware to enable firmware functionality, each transmitter, receiver, or expansion card using the same processor 36 uses the same firmware, and the processor is configured to identify the hardware version and implement the firmware accordingly.

[0382] Those skilled in the art will understand that the application of this disclosure is not limited to the details of the construction and the arrangement of components as stated in the foregoing description or illustrated in the accompanying drawings. The embodiments described herein can have other embodiments and can be practiced or implemented in various ways. Furthermore, it should be understood that the wording and terminology used herein are for descriptive purposes only and should not be considered limiting. The use of “comprising,” “including,” or “having,” and variations thereof herein means to cover items listed below and their equivalents, as well as additional items. Unless otherwise limited, the terms “connected,” “coupled,” and “mounted,” and variations thereof are widely used herein and cover direct and indirect connections, couplings, and mounts. Additionally, the terms “connected” and “coupled,” and variations thereof, are not limited to physical or mechanical connections or couplings. Furthermore, terms such as upper, lower, bottom, and top are relative and used for illustrative purposes, not for limitation.

[0383] The components of the illustrative apparatus, systems, and methods employed according to the described embodiments may be implemented at least in part as digital electronic circuit systems, analog electronic circuit systems, or as computer hardware, firmware, software, or a combination thereof. For example, these components may be implemented as computer program products, such as computer programs, program code, or computer instructions tangibly embodied in an information carrier or machine-readable storage device, for execution or control of their operation by a data processing device (e.g., a programmable processor, a computer, or multiple computers).

[0384] Computer programs can be written in any programming language, including compiled or interpreted languages, and can be deployed in any form, including as standalone programs or as modules, components, subroutines, or other units suitable for use in a computing environment. Computer programs can be deployed to execute on a single computer, or distributed across multiple computers at one site or across multiple sites interconnected by a communication network. Furthermore, the functional programs, code, and code segments used to implement the illustrative embodiments are readily interpreted by those skilled in the art to which the illustrative embodiments pertain as being within the scope of the claims exemplified in the illustrative embodiments. The method steps associated with the illustrative embodiments can be executed by one or more programmable processors that execute computer programs, code, or instructions to perform functions (e.g., by manipulating input data and / or generating output). The method steps can also be executed by a dedicated logic circuit system, and the devices of the illustrative embodiments can be implemented as dedicated logic circuits, for example, FPGAs (Field-Programmable Gate Arrays) or ASICs (Application-Specific Integrated Circuits).

[0385] The various illustrative logic blocks, modules, and circuits described in conjunction with the embodiments disclosed herein may be implemented or executed using a general-purpose processor, digital signal processor (DSP), ASIC, FPGA, or other programmable logic device designed to perform the functions described herein, discrete gate or transistor logic, discrete hardware components, or any combination thereof. The general-purpose processor may be a microprocessor, but alternatively, the processor may be any conventional processor, controller, microcontroller, or state machine. The processor may also be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, multiple microprocessors, one or more microprocessors integrated with a DSP core, or any other such configuration.

[0386] By way of example, processors suitable for executing computer programs include both general-purpose and special-purpose microprocessors, as well as any one or more processors of any kind of digital computer. Typically, a processor receives instructions and data from read-only memory or random access memory, or both. The basic components of a computer are a processor for executing instructions and one or more memory devices for storing instructions and data. Typically, a computer also includes one or more mass storage devices (e.g., magnetic disks, magneto-optical disks, or optical disks) for storing data, or operatively coupled to receive data from or transfer data to said one or more mass storage devices, or both. Information carriers suitable for embodying computer program instructions and data include all forms of non-volatile memory, including, by way of example, semiconductor memory devices, such as electrically programmable read-only memory or ROM (EPROM), electrically erasable programmable ROM (EEPROM), flash memory devices, and data storage disks (e.g., magnetic disks, internal hard disks, or removable disks, magneto-optical disks, and CD-ROM and DVD-ROM disks). The processor and memory may be supplemented by or incorporated into a dedicated logic circuit system.

[0387] Those skilled in the art will understand that information and signals can be represented using any of a variety of different technologies and techniques. For example, data, instructions, commands, information, signals, bits, symbols, and chips that may be referenced throughout the above description can be represented by voltage, current, electromagnetic waves, magnetic fields or magnetic particles, light fields or optical particles, or any combination thereof.

[0388] Those skilled in the art will further understand that the various illustrative logic blocks, modules, circuits, and algorithm steps described in conjunction with the embodiments disclosed herein can be implemented as electronic hardware, computer software, or a combination of both. To clearly illustrate this interchangeability between hardware and software, the various illustrative components, blocks, modules, circuits, and steps have been described above generally in relation to their functionality. Whether such functionality is implemented as hardware or software depends on the specific application and the design constraints imposed on the overall system. Those skilled in the art may implement the described functionality in different ways for each specific application, but such implementation decisions should not be construed as causing a departure from the scope of the claims exemplified by the illustrative embodiments. Software modules may reside in random access memory (RAM), flash memory, ROM, EPROM, EEPROM, registers, hard disks, removable disks, CD-ROMs, or any other form of storage media known in the art. An exemplary storage medium is coupled to a processor such that the processor can read information from and write information to the storage medium. Alternatively, the storage medium may be integrated into the processor. In other words, the processor and storage medium may reside in an integrated circuit or be implemented as discrete components.

[0389] Computer-readable non-transitory media encompasses all types of computer-readable media, including magnetic storage media, optical storage media, flash memory media, and solid-state storage media. It should be understood that software may be installed in and sold with a central processing unit (CPU) device. Alternatively, software may be obtained and loaded into a CPU device, including obtaining software via physical media or a distribution system, such as from a server owned by the software creator or from a server used by the software creator. For example, software may be stored on a server for distribution via the Internet.

[0390] The description and figures presented above are intended to be illustrative only and are not intended to limit the illustrative embodiments in any way, except as set forth in the following claims. It should be noted that those skilled in the art can readily combine various technical aspects of the various elements of the various illustrative embodiments described above in many other ways, all of which are considered to be within the scope of the claims.

Claims

1. A kit comprising at least one transmitter and at least one receiver, the at least one transmitter and at least one receiver being configured to pair for wireless communication with each other to control the operation of one or more radio-controlled machine (RCM) devices; Each of the at least one receiver has an electrical output connected to a corresponding electric control element in the radio control machine; and Each of the at least one transmitter has a configurable user input interface, the transmitter being operable to generate a command signal for operating one or more of the electric controls in response to user manipulation of a corresponding entity in the user input interface, and to send the command signal to the receiver, the receiver being operable to provide an output signal to the corresponding one or more of the electric controls so that it operates according to the command signal.

2. The kit of claim 1, wherein the kit further comprises an RCM configuration generator application for creating a configuration file for at least one of the at least one transmitters, the configuration file describing a mapping of the user input interface to the output signal of the at least one receiver corresponding to the transmitter movement speed / direction selection.

3. The kit of claim 2, wherein the kit further includes an RCM interface application configured for user access, manipulation and visualization of details of at least one of the one or more RCM devices.

4. The kit according to claim 3, wherein the RCM interface application is a Windows operating system application.

5. The kit of claim 4, wherein a user can connect at least one of the one or more RCM devices to a Windows-based computer via a USB connection and manipulate and interact with the RCM device to perform one or more tasks selected from transferring configuration settings, retrieving operation logs, and initiating equipment diagnostics.

6. The kit of claim 3, wherein the RCM interface application is configured to process the configuration file and transmit configuration settings therefrom to the transmitter.

7. The kit of claim 1, wherein the kit further includes a DIP switch disposed on the at least one transmitter and the at least one receiver and configured to allow a user to form a DIP switch setting for the corresponding one of the at least one transmitter and the at least one receiver.

8. The kit of claim 7, wherein the kit further includes a battery compartment disposed in the at least one transmitter and configured to accommodate one or more removable batteries, and wherein the DIP switch is accessible in the battery compartment.

9. The kit of claim 7, wherein the DIP switch disposed on the at least one transmitter is configured to assign a function to a configurable user input interface on the transmitter, the function being selected from motion functions and auxiliary functions, wherein the auxiliary functions are selected from A / B transmitter functionality, single relay contact enable function, and instantaneous / switching on-off, inactivity time selection.

10. The kit of claim 7, wherein the DIP switch disposed on the at least one receiver is configured with a DIP switch setting array that allows a user to configure unique settings for the receiver for features selected from: DIP switch control or RCM configuration selection, relay output for speed operation, external buzzer presence, channel selection, and system configuration.

11. The kit of claim 1, wherein the at least one transmitter and at least one receiver are configured to pair for operation configurations selected from throw and capture, cooperative and drag-free.

12. A transmitter for controlling the operation of a remotely controlled machine (RCM) device, the RCM device having one or more electrically operated controls for moving at least one component associated with the RCM device, the transmitter comprising: An antenna configured to wirelessly transmit radio frequency signals to one or more remote receivers paired with the transmitter; Configurable user input interface; A battery compartment configured to receive one or more batteries; Battery monitor / power management circuit; and A processor connected to the antenna, the configurable user input interface, and the battery monitor / power management circuitry; The processor is configured to generate command signals for operating one or more of the electric controls in response to user manipulation of the corresponding user input interface, and to send the command signals to the one or more remote receivers.

13. The transmitter of claim 12, wherein the battery monitor / power management circuitry includes an electrically erasable programmable read-only memory (EEPROM).

14. The transmitter of claim 12, wherein the battery monitor / power management circuit is programmed to monitor the current supplied by the one or more batteries and the voltage of the one or more batteries to determine the expected remaining operating time of the transmitter.

15. The transmitter of claim 12, wherein the battery monitor / power management circuit is programmed to track the charging cycles, initial ampere-hour capacity, and current ampere-hour capacity of the one or more batteries.

16. The transmitter of claim 12, wherein the battery compartment is configured for quick-connect battery compartment to electrically connect the one or more batteries to power any of the antenna, the processor, the battery monitor / power management circuitry and other components in the transmitter.

17. The transmitter of claim 12, further comprising a USB-C connection.

18. The transmitter of claim 17, wherein the one or more batteries are charged via the USB-C connection or a remote battery charger for removable batteries.

19. The transmitter of claim 17, wherein the user can use the USB-C connection to access the transmitter's data log, which includes information selected from RCM device operation, fault occurrence, operation time, pairing configuration, and the status of the one or more batteries.

20. The transmitter of claim 12, further comprising an indicator for indicating at least one of battery health, pairing status with the one or more receivers, and a fault.

21. The transmitter of claim 12, further comprising a pendulum switch mounted therein, and the processor being programmed to monitor the pendulum switch and disable the transmitter when the pendulum switch tilts a selected degree from a specified normal forward / backward position and a specified normal backward / forward position.

22. The transmitter of claim 12, further comprising a display, and the processor being programmed to communicate information to an operator via the display, the information being selected from motion indication, maintenance mode, diagnostics, battery status, pairing selection, device name of each of the one or more receivers paired with the transmitter, emergency stop switch activation status, and tilt warning.

23. The transmitter of claim 12, wherein the transmitter is disposed in a housing having a configurable toggle switch and an auxiliary switch selected from push-button switches, two-position toggle switches, three-position toggle switches, two- to ten-position configurable selector switches, and analog switches.

24. The transmitter of claim 23, wherein the two- to ten-bit configurable selector switch and the analog switch each have a dedicated input to the processor.

25. The transmitter of claim 23, wherein the abdominal housing comprises: The instrument surface on which the configurable toggle switch and the auxiliary switch are arranged; And a cage rod, which is mounted outside the abdominal housing and extends from the surface of the instrument, to prevent accidental activation of the paddle switch and the auxiliary switch in the event of a drop of the transmitter.

26. The transmitter of claim 25, wherein the cage bar includes at least one curved portion providing a hand grip portion that ergonomically supports the user's hand when operating the transmitter.

27. The transmitter of claim 12, further comprising RCM interface software for providing user configuration settings to the transmitter, and the RCM interface software for communicating information to the processor to configure the radio frequency signals transmitted to the one or more receivers to implement the desired function of the electric control element of the RCM device.

28. A receiver for controlling the operation of a remotely controlled machine (RCM) device, the RCM device having one or more electrically controlled elements for moving at least one component associated with the RCM device, the receiver comprising: An antenna configured to wirelessly receive radio frequency control signals from a remote transmitter; A power interface that is coupled to the power supply of the RCM device; processor; and Multiple configurable control outputs; The processor is configured to process signals received from a remote transmitter via the antenna and to generate corresponding output signals to the one or more electric controllers in the RCM device via at least one of the plurality of configurable control outputs, so as to control the one or more electric controllers in the RCM device.

29. The receiver of claim 28, wherein the receiver includes a Controller Area Network (CANbus) interface for communicating with one or more external cards to control the operation of the RCM device.

30. The receiver of claim 29, wherein the external card can be mounted to the receiver via either a snap-on track or a housing mount.

31. The receiver of claim 29, wherein the external card includes an output selected from the following: a relay output for operating an AC or DC RCM device, an analog output for controlling a variable frequency drive RCM device, and a latching relay output for maintaining the current state of the electric control unit during a power outage.

32. The receiver of claim 29, wherein each of the external cards includes at least one indicator of a fault occurrence.

33. The receiver of claim 28, further comprising at least one indicator operated by the processor to indicate the status of the receiver, the status being selected from power status, pairing status, CANbus status, and fault occurrence.

34. The receiver of claim 28, further comprising a DIP switch for configuring unique receiver settings for the receiver for features selected from: configuration selection controlled by the DIP switch or configured by RCM interface software, relay output speed operation, external buzzer presence, channel selection, and system configuration.

35. A receiver for controlling the operation of a remotely controlled machine (RCM) device, the RCM device having one or more electrically controlled elements for moving at least one component associated with the RCM device, the receiver comprising: An antenna configured to wirelessly receive radio frequency signals; A power interface that is coupled to the power supply of the RCM device; processor; and Multiple card slots, each configured to removably receive an expansion card selected from a set of expansion cards having different types of control outputs, wherein multiple control outputs of the expansion cards connected to the corresponding cards in the multiple card slots can be configured depending on the type of the RCM device and the operation to be controlled by the RCM device; The processor is configured to process signals received from a remote transmitter via the antenna and generate corresponding output signals to the one or more electric controllers in the RCM device via at least one of the plurality of configurable control outputs to control the one or more electric controllers in the RCM device. The configurable control output is selected from a number of control output types, including: Type A relay contact output, Type C relay contact output, DC relay output, latching relay output, and analog output.

36. The receiver of claim 35, wherein the number of configurable control outputs is selectable from a range of 1 to 48 control outputs.

37. The receiver of claim 35, wherein the set of expansion cards includes expansion cards configured with corresponding of the plurality of control output types.

38. The receiver of claim 35, wherein the antenna receives radio frequency signals from the remote transmitter according to a 900 MHz wireless communication protocol.

39. The receiver of claim 35, further comprising a Controller Area Network (CANbus) interface.

40. The receiver of claim 38, wherein at least one of the expansion cards connected to the corresponding cards in the plurality of card slots includes a Controller Area Network (CANbus) interface.

41. The receiver of claim 35, further comprising at least one of: an indicator selected from an optical indicator for indicating the diagnostic status of the receiver, an optical indicator mounted externally to the receiver, an audible indicator mounted externally to the receiver; and a connector configured to connect to the external audible indicator.

42. The receiver of claim 40, wherein the processor is configured to operate the indicator to output a first type of indication corresponding to the receiver being powered on, and to output a second type of indication corresponding to the receiver and the processor being operated to process a signal received from the remote transmitter and generate the corresponding output signal.

43. The receiver of claim 41, wherein the processor is configured to operate the indicator to output a third type of indication corresponding to the receiver being paired with the remote transmitter, and to output a fourth type of indication corresponding to at least one of receiver failure and the receiver being unable to pair with the remote transmitter.

44. The receiver of claim 35, further comprising a configurable power supply.

45. The receiver of claim 35, further comprising at least one external card mounted to the receiver via a snap-fit ​​rail or housing and mounted via a CANbus interface.

46. ​​The receiver of claim 44, wherein the at least one external card can have an output selected from the following: a relay output for operating an AC RCM device, a DC RCM device, an analog output for controlling an RCM device with a variable frequency device, and a latching relay output for maintaining the current state during a power outage.

47. The receiver of claim 38, further comprising an external expansion card connected to the receiver via a Controller Area Network Bus (CANbus) interface.

48. The receiver of claim 46, wherein the number of configurable control outputs is selectable from a range of 1 to 256 control outputs via the external expansion card.

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