Improved mechanisms for rotating devices

Abstract

A directional control device for controlling the rotational direction of a load suspended from an apparatus comprises a housing or framework for coupling to the load. In some embodiments, at least one torque-generating device is attached to the housing or framework. In some embodiments, an electric frictionless swivel is coupled directly or indirectly to the housing or framework and to one or more lines suspending the load. The apparatus further comprises a controller in communication with the at least one torque-generating device and the electric frictionless swivel, and controls the rotational direction of the load by controlling the ratio of rotational forces imparted to the load from the at least one torque-generating device and the electric frictionless swivel. According to some embodiments, the apparatus comprises one or more thrusters movably attached, directly or indirectly, to the housing or framework via one or more mounting elements to change its position from the center of the housing or framework, and the controller is in communication with the one or more thrusters and controls the ratio of rotational forces imparted to the load from the one or more thrusters.

Description

[Technical field]

[0001] The present invention relates to an improved arrangement for a rotation device. In particular, embodiments of the present invention relate to an improved arrangement and related method for a directional control device for a large load. [Background technology]

[0002] In industries such as, but not limited to, transportation and construction, loads are lifted, moved and repositioned many times before being placed in a final location. Moving a suspended load, for example via a crane, can endanger surrounding workers and structures. While certain aspects of movement can be controlled by a crane, load rotation is often unpredictable and can be suddenly affected by environmental factors such as wind and / or the nature of the load itself. It is known to use one or more gyroscopes to control load rotation. Indeed, the applicant has devised improved load management systems and methods for tracking and controlling loads that include a control moment gyroscope (CMG) module. In these systems and methods, the orientation of a suspended load is controlled by transferring angular momentum within a control moment gyro module. The applicant's improved load management systems and methods are the subject of International Patent Application PCT / AU2016 / 050941, the entirety of which is incorporated herein by reference.

[0003] Additionally, techniques utilizing other physical principles to achieve rotational control are known, such as the use of fans and the movement of liquids around enclosed chambers. However, none of these techniques address the problems faced by very heavy, long and / or large loads. For example, one feature of Applicant's prior art devices is the ability to measure both the size and number of individual gyro modules, which, while making the system quite adaptable, space, weight and / or economic constraints may require additional capabilities to achieve a viable solution.

[0004] The limitations of conventional systems arise in the case of very heavy, very long or large loads. One example of such a load is a wind turbine blade. Wind turbine blades are very long compared to their mass, which creates a very large rotational inertia compared to their mass and can result in very large, lopsided wind loads. In contrast, there are offshore structural components such as large vertical columns or pipes that have a very high concentration of mass, and therefore the friction in the swing between the crane hook and the crane hoist rope becomes a significant factor in the total torque required to orient the load.

[0005] The reference in this specification to any prior art is not, and should not be construed as, an acknowledgment or any form of suggestion that that prior art forms part of the common general knowledge. Summary of the Invention [Problem to be solved by the invention]

[0006] It is a desired object of the present invention to provide an improved mechanism and / or method for a rotational device, and in particular an improved directional control device, which solves or at least ameliorates one or more of the above-mentioned problems of the prior art and / or provides a useful commercial alternative. [Means for solving the problem]

[0007] In general, the present invention relates to an improved mechanism for a rotational device, and more particularly to a rotational control device for controlling the rotational orientation of a large load suspended from the device, and an associated method.

[0008] In one form, not necessarily its broadest or only form, the present invention provides a directional control device for controlling the rotational orientation of a load suspended from the device, comprising: a housing or framework for coupling to the load; at least one gyroscope or gyro module mounted in a housing or framework; one or more thrusters movably attached, directly or indirectly, to the housing or framework via one or more mounting elements to vary their position from a center of the housing or framework; a control device in communication with the at least one gyroscope or gyro module, the one or more thrusters, and the one or more mounting elements, and configured to control a ratio of rotational forces imparted to the load from the at least one gyroscope or gyro module and the one or more thrusters, thereby controlling a rotational orientation of the load; The device comprises:

[0009] Preferably, the device includes a powered frictionless swivel coupled directly or indirectly to the housing or framework and coupled to one or more lines suspending the load, and a controller in communication with the powered frictionless swivel to control the rate of rotational force imparted to the load by the powered frictionless swivel.

[0010] In another embodiment, not necessarily in its broadest form, the present invention provides a directional control device for controlling the rotational orientation of a load suspended from the device, comprising: a housing or framework for coupling to the load; at least one torque generating device attached to a housing or framework; an electrically powered frictionless swivel connected directly or indirectly to the housing or framework and connected to one or more lines from which a load is suspended; a control device that communicates with the at least one torque generating device and the electric frictionless swivel and controls a ratio of rotational forces applied to the load from the at least one torque generating device and the electric frictionless swivel, thereby controlling a rotational direction of the load; The device comprises:

[0011] Preferably, the device comprises one or more thrusters movably attached directly or indirectly to the housing or framework via one or more mounting elements to vary its position from the center of the housing or framework, and a control device communicates with the one or more thrusters and controls the ratio of rotational forces imparted to the load from the one or more thrusters.

[0012] In another embodiment, not necessarily in its broadest form, the present invention provides a directional control device for controlling a rotational orientation of a load suspended from the device, comprising: a housing or framework for coupling to the load; an electrically powered frictionless swivel connected directly or indirectly to the housing or framework and connected to one or more lines from which a load is suspended; one or more thrusters movably attached, directly or indirectly, to the housing or framework via one or more mounting elements to vary their position from a center of the housing or framework; a control device that communicates with the electric frictionless swivel and the one or more thrusters and controls a ratio of rotational forces applied to the load from the electric frictionless swivel and the one or more thrusters, thereby controlling a rotational direction of the load; Equipped with.

[0013] Preferably, the apparatus includes at least one torque generating device mounted to the housing or framework, and a control device in communication with the at least one torque generating device and controlling the ratio of rotational force imparted to the load from the at least one torque generating device.

[0014] In another form, not necessarily in its broadest form, the present invention provides a method of controlling rotational orientation of a load, comprising: coupling a housing or framework to a load; mounting at least one torque generating device on a housing or framework; movably mounting, directly or indirectly, one or more thrusters to a housing or framework via one or more mounting elements to vary a position of the one or more thrusters from a center of the housing or framework; controlling a rotational orientation of the load by controlling a ratio of rotational forces imparted to the load from the at least one torque generating device and the one or more thrusters via a controller in communication with the at least one torque generating device, the one or more thrusters, and the one or more attachment elements; Includes:

[0015] Preferably, the method includes coupling a powered frictionless swivel directly or indirectly to a housing or framework and to one or more lines suspending a load, and a controller in communication with the powered frictionless swivel to control the rate of rotational force imparted from the powered frictionless swivel to the load.

[0016] In another embodiment, the present invention provides a method for controlling the orientation of a load, the method comprising: coupling a housing or framework to a load; mounting at least one torque generating device on a housing or framework; connecting, directly or indirectly, an electric frictionless swivel to a housing or framework and to one or more lines from which a load is suspended; controlling a rotational orientation of the load by controlling a ratio of rotational forces imparted to the load from the at least one torque generating device and the powered frictionless swivel via a controller in communication with the at least one torque generating device and the powered frictionless swivel; Includes:

[0017] Preferably, the method includes a step of movably mounting one or more thrusters directly or indirectly to the housing or framework via one or more mounting elements to vary a position of the one or more thrusters from a center of the housing or framework, and a controller in communication with the one or more thrusters to control the ratio of rotational forces imparted to the load from the one or more thrusters.

[0018] In another embodiment, the present invention provides a method for controlling the orientation of a load, the method comprising: coupling a housing or framework to a load; connecting, directly or indirectly, an electric frictionless swivel to a housing or framework and to one or more lines from which a load is suspended; movably mounting one or more thrusters, directly or indirectly, to a housing or framework via one or more mounting elements to vary a position of the one or more thrusters from a center of the housing or framework; controlling a rotational orientation of the load by controlling a ratio of rotational forces imparted to the load from the electric frictionless swivel and the one or more thrusters by a controller in communication with the electric frictionless swivel and the one or more thrusters; Includes:

[0019] Preferably, the method includes the steps of attaching a housing or framework to at least one torque generating device and controlling the rate of rotational force imparted to the load from the at least one torque generating device via a controller in communication with the at least one torque generating device.

[0020] Preferably, the at least one torque generating device is selected from a gyroscope, a gyro module (unit or device), a control moment gyroscope (CMG), a flywheel, a rotating mass (e.g., but not limited to, a mass of fluid moving around a closed gap), or other rotating device capable of applying a torque to a load.

[0021] In some embodiments, the directional control device comprises a torque generating device in the form of one or more resistance elements or mechanisms that generate resistance in the presence of wind. Preferably, the position and / or orientation of the one or more resistance elements or mechanisms is adjustable to vary the resistance, and therefore the torque, generated by the one or more resistance elements or mechanisms.

[0022] Preferably, one or more resistance elements or mechanisms are coupled to the load and offset from the center of the housing or framework.

[0023] Preferably, the one or more resistive elements or mechanisms are communicatively coupled to the controller and the power source.

[0024] In some embodiments, the one or more resistance elements or features comprise one or more slats or plates.

[0025] Suitably, one or more slats or plates are mounted on a rotatable rod or bar or the like driven by a drive means, and the orientation of the one or more resistance elements or mechanisms is adjustable to vary the resistance, and therefore the torque, generated by the one or more resistance elements or mechanisms.

[0026] Preferably, the angle of incidence of one or more slats or plates to the wind can be adjusted about the axis of the rod or bar to vary the resistance coefficient of the one or more slats or plates to the wind, thereby varying the torque about the centre of the load due to resistance.

[0027] In some embodiments, the location of one or more resistance elements or mechanisms from the center of the load is adjustable or variable.

[0028] Preferably, the electric frictionless swivel comprises a top or stator and a drive means within which a bottom or rotor rotates relative to the top or stator on a thrust bearing, and the drive means rotates the bottom relative to the top.

[0029] In some embodiments, the device further comprises one or more sensors in communication with the controller for measuring the rotational speed of the top or stator and bottom or rotor of the motorized frictionless swivel.

[0030] In some embodiments, the apparatus further comprises one or more sensors in communication with the controller for measuring the rotational speed of the crane boom.

[0031] Preferably, the electric frictionless swivel is used for one or more of the following purposes: to ease the load while initiating a load rotation, to ease the load while maintaining the load rotation, for braking purposes, and to hold the load in a set orientation.

[0032] Further aspects and / or embodiments and / or features of the present invention will become apparent from the following detailed description. [Brief description of the drawings]

[0033] In order that the invention may be readily understood and put into practice, reference will now be made to preferred embodiments thereof with reference to the accompanying drawings, in which identical elements are designated by like reference numerals and in which: [Figure 1] FIG. 1 is a front view of a direction control device for controlling the rotational orientation of a suspended load according to a first embodiment of the present invention. [Diagram 2] FIG. 2 is a plan view of the device shown in FIG. [Diagram 3] FIG. 3 is a front view of an electric frictionless swivel including a portion of the device shown in FIG. [Figure 4]FIG. 4 is a cross-sectional view of the electric frictionless swivel shown in FIG. [Diagram 5] FIG. 5 is a front perspective view of the electric frictionless swivel shown in FIG. [Figure 6] FIG. 6 is a schematic diagram of elements of the apparatus shown in FIG. [Figure 7] FIG. 7 is a plan view of the apparatus shown in FIG. 1 illustrating operation according to one mode of operation. [Figure 8] FIG. 8 is a plan view of the apparatus shown in FIG. 1 illustrating operation according to another mode of operation. [Figure 9] FIG. 9 is a general flow diagram illustrating a method for controlling load orientation in accordance with some embodiments of the present invention. [Figure 10] FIG. 10 is a front view of a directional control device for controlling the rotational orientation of a suspended load in accordance with another embodiment of the present invention. [Figure 11] FIG. 11 is a plan view of the direction control device shown in FIG. [Figure 12] FIG. 12 is a side view illustrating the operation of the aerodynamic resistance mechanism of the direction control device shown in FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0034] Those skilled in the art will appreciate that the elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the relative dimensions of some of the elements in the figures may be distorted to facilitate understanding of embodiments of the present invention. Some of the elements of the device may be omitted from some figures for clarity.

[0035] SUMMARY OF THE DISCLOSURE Embodiments of the present invention relate to improved mechanisms for rotational devices and directional control devices, particularly for controlling the rotational orientation of large loads suspended from the device, and associated methods.

[0036] According to some embodiments, the directional control device includes an auxiliary torque source to provide overall and precise control of the load's rotational position. According to some embodiments, the auxiliary torque source is a fan, multiple fans, or other type of thruster, having constant thrust, and therefore torque, characteristics that increase in effectiveness with increasing distance from the center of gravity.

[0037] According to some embodiments, the directional control device includes a mechanical drive between the crane hook and the top of the crane hook swivel to force relative rotation between the hook and hook block, effectively eliminating the friction inherent in the crane hook swivel, on demand.

[0038] According to some embodiments, the directional control device comprises a controller or control system that controls the ratio of rotational forces imparted to the load from different components of the device or system that provide torque to enable control of very large loads. The components of the system contribute to the rotational forces as needed in a tightly controlled manner. The controller or control system optimizes every aspect of the components to provide the most effective directional output and control under various loads and environmental conditions. The different characteristics of each component that provides the rotational forces, e.g., one or more torque generating devices, one or more gyroscope or gyro modules / units / devices, powered swivels, and one or more fans / thrusters, provide a high degree of freedom in configuring the complete system for flexibility and scalability.

[0039] According to some embodiments, the directional control device constitutes a sub-module of the control system for: a) using one or more fans to reduce load swing when the tip of the crane is moving, for example in an offshore environment due to the vessel carrying the crane being in motion, b) providing a damping effect by cycling one or more fans on and off, c) directly applying thrust for lateral / longitudinal movement in addition to or instead of rotation.

[0040] According to some embodiments, the method control device is equipped with a power source for situations that may be encountered, for example to be able to control very large loads over long periods of time. According to some embodiments, one or more energy sources may be used, such as diesel generators and / or high performance batteries. Another option is to use an external power source to spin a torque generating device, such as a gyroscope / gyro module, before the lift and use this to feed back to the on-board power source during the lift. A further option is to use the energy stored in the gyroscope rotor from time to time, and feed it back into the system for use by other devices.

[0041] Embodiments of the present invention provide a viable method for minimizing manual handling of suspended loads across a much wider range of load types and environmental conditions.

[0042] 1 and 2. According to some embodiments of the present invention, a directional control device 100 for controlling the rotational orientation of a load 102 suspended from the directional control device 100 comprises a housing or frame 104, such as a blade yoke for coupling to the load 102, and at least one torque generating device 106 attached to the housing or framework 104. The at least one torque generating device 106 is selected from the following: a gyroscope, a gyro module (unit or device), a control moment gyroscope (CMG), a flywheel, a rotating mass (e.g., but not limited to, a mass of a fluid moving around a closed air gap), or other rotating device that can apply a torque to the load. The directional control device 100 comprises one or more thrusters, or thrust devices 108, movably attached directly or indirectly to the housing or framework 104 via one or more mounting elements 110 to vary the position of the thrusters 108 from the center of the housing or framework 104. In this embodiment, the device includes a pair of thrusters 108, while other embodiments may include one thruster 108 or two or more thrusters 108. In this embodiment, the thrusters 108 are attached to the housing or frame 104 via respective telescopic arms 112. The directional control device 100 includes a controller 114 that is in communication with the at least one torque generating device 106, the pair of thrusters 108, and the one or more mounting elements 110 to control the rotational orientation of the load 102 by controlling the ratio of rotational forces imparted to the load 102 from the at least one torque generating device 106 and the pair of thrusters 108. Thus, in some embodiments, the controller 114 controls the ratio of rotational forces imparted to the load from at least two sources: the at least one torque generating device 106 (e.g., gyroscope, gyro module / unit / device, flywheel, etc.) and the one or more thrusters 108.

[0043] According to some embodiments shown in Figures 1 and 2, the directional control device 100 includes a motorized frictionless swivel 116 that is directly or indirectly coupled to the housing or framework 104 and coupled to one or more lines 118 from which the load 104 is suspended. In this embodiment, the motorized frictionless swivel 116 is indirectly coupled to the housing or framework 104 via a number of hoist lines 120, which are coupled to the lines 118 from which the load 102 is suspended, for example, from a crane (not shown). In this embodiment, the controller 114 is in communication with the motorized frictionless swivel 116 and further controls the ratio of rotational force imparted to the load from the motorized frictionless swivel 116. Thus, according to some embodiments shown in Figures 1 and 2, the controller 114 controls the ratio of rotational force imparted to the load from at least three sources: at least one torque generating device 106, one or more thrusters 108, and the motorized frictionless swivel 116.

[0044] The directional control device 100 includes a power source or power source 132 coupled to at least one torque generating device 106 , one or more thrusters 108 , a mounting element 110 and a motorized frictionless swivel 116 .

[0045] According to another embodiment, a directional control device 100 for controlling a rotational orientation of a load 102 suspended from the directional control device 100 includes a housing or framework 104 for coupling to the load 102, at least one torque generating device 106 attached to the housing or framework, a motorized frictionless swivel 116 coupled directly or indirectly to the housing or framework 104 and coupled to one or more lines 118 suspending the load, and a controller 114. In such an embodiment, the controller 114 is in communication with the at least one torque generating device 106 and the motorized frictionless swivel 116 and controls the ratio of rotational forces imparted to the load 102 from the at least one torque generating device 106 and the motorized frictionless swivel 116, thereby controlling the rotational orientation of the load 102.

[0046] According to a further embodiment, a directional control device 100 for controlling a rotational orientation of a load 102 suspended from the directional control device 100 includes a housing or framework 104 for coupling to the load 102, a motorized frictionless swivel 116 coupled directly or indirectly to the housing or framework 104 and coupled to one or more lines 118 from which the load is suspended, one or more thrusters 108 movably attached directly or indirectly to the housing or framework 104 via one or more mounting elements 110 for varying its position from a center of the housing or framework 104, and a controller 114. In such an embodiment, the controller 114 is in communication with the motorized frictionless swivel 116 and the one or more thrusters 108 to control the ratio of rotational forces imparted to the load 102 from the motorized frictionless swivel 116 and the one or more thrusters 108, thereby controlling the rotational orientation of the load 102.

[0047] Thus, different embodiments of the directional control device 100 of the present invention include different combinations of rotational force sources or torques that can be individually and simultaneously controlled to provide the desired rotational force or torque to control the rotational orientation of the load according to the particular application.

[0048] The one or more movable mounting elements 110 for varying the position of the one or more thrusters 108 can be in the form of a telescopic frame or arm as shown in Figures 1 and 2, or other movable elements such as hinged, folding or rotating arms, frames or rods to provide variable separation from the center of gravity during operation. In other embodiments, the one or more thrusters 108 can be attached to the rigging using special purpose or standard spreader bars. In some embodiments, the one or more mounting elements 110 can be attached to the load 102 during operation and can be attached to the rigging for transportation and setup. In other embodiments, it is envisioned that the one or more thrusters 108 are attached to respective drones that are flown into position at both ends of the load 102 and attached thereto by any suitable means. The thrust from the drones is reoriented from vertical to horizontal. After the lift is complete, the drones can be returned to the rigging and reattached by any suitable means. The drones can be tethered or free flying.

[0049] The one or more thrusters 108 may be in the form of a fan, such as a bidirectional fan, a fixed pitch fan, a variable pitch fan, a single speed fan, a variable speed fan, a direct thrust fan, a vectored thrust fan, etc., and may be gasoline or battery powered, for example. The fan may be standalone having its own power source or may be powered from a central power source 132 of the vector control device 100. In other embodiments, a hybrid power source is used, with the vector control device 100 using an on-board battery that charges while plugged in and a control hub that is not part of the vector control device 100.

[0050] With reference to Figures 3-5, according to some embodiments, the motorized frictionless swivel 116 includes a top or stator 122 within which a bottom or rotor 124 rotates on a thrust bearing 126 relative to the top or stator 122. A drive means 128, such as an electric motor, is attached to the bottom or rotor 124. The drive means 128 includes a spur gear (not shown) attached thereto that engages a ring gear (not shown) attached to or part of the interior of the top or stator 122. The drive means 128 may be any form of electromechanical, hydraulic, or other drive means capable of imparting a relative torque. In some embodiments, power may be provided by a battery, motor, or generator, which may be attached to the top of the crane hook and may be supplied from the same source as the rotation mechanism. In some embodiments, the power source may be a power source 132 as described herein. In some embodiments, one or more sensors 136 in communication with the controller 114 measure the rotational speed of the top or stator 122 and bottom or rotor 124 of the motorized frictionless swivel 116, and one or more sensors (not shown) in communication with the controller 114 measure the rotational speed of the crane boom. In some embodiments, the power and control cables 130 may run along slings, chains, or the like to the power source 132 and controller. The drive means 128 is operated to rotate the bottom or rotor 124 relative to the top or stator 122. The motorized frictionless swivel 116 may be used to reduce the load at least to initiate and maintain rotation of the load 102. To brake faster at the end of the load rotational movement, the motorized frictionless swivel 116 may be turned off or torqued back.

[0051] There are various loads that a rotation mechanism controlling the orientation of a suspended load must overcome. Such loads include load rotation characteristics that are a function of the load characteristics and are stable. Such loads further include torque due to friction of the crane hook swivels and bias wind pressure on the load 102 and rigging, both of which vary. The relative contributions of the two external effects vary with wind speed and the ratio of load inertia to the area of ​​the mechanism 138, which includes one or more resistance elements or one or more slats or plates 140, as described herein.

[0052] In the absence of wind effects, after the rotation mechanism begins to rotate the load 102, the friction of the swivel alone stops the load 102 from rotating. If sufficient torque can be applied to the bottom or crane hook rotor 124 rotating relative to the non-rotating top or stator 122, the effect of the swivel friction can be countered and the rotating load 102 will continue to rotate without the need for additional input from the primary rotation mechanism. If the control system is configured to receive input from both the top and bottom of the hook with respect to rotation rate and direction, the torque applied to rotate the hook bottom or rotor 124 will cause the bottom or rotor 124 to rotate at the same speed as the rotation mechanism is moving the suspended load 102. When this condition is achieved, the swivel can be effectively frictionless relative to the rotation mechanism.

[0053] In the presence of biased wind loads that reduce the ability of the rotation mechanism to rotate a load, the torque imparted by the motorized swivel 116 can be used to augment the torque generated by the rotation mechanism by making the torque imparted to the bottom of the hook or rotor 124 greater than the torque required to overcome swivel friction, in which case the motorized swivel 116 increases the effective rotation capability of the rotation mechanism.

[0054] Conversely, if the load 102 is rotating and needs to be slowed or stopped, applying a reverse torque to the bottom or rotor 124 of the hook relative to the top or stator 122 will stop the load 102, effectively increasing the braking capacity of the rotation mechanism.

[0055] In all cases some limited amount of twist is allowed, but the torque generated by the motorized swivel 116 cannot exceed the torsional stiffness of the crane hoist rope such that a torque is applied to the rope. A sensor 136 on the non-rotating top of the hook or on the stator 122 monitors whether the hoist rope is approaching the limit of allowable twist. When the crane is swiveling, an additional sensor (not shown) on the crane boom is required to compensate or would give an incorrect reading of the actual hoist rope twist.

[0056] In summary, having the ability to apply torque between the upper and lower parts of the crane hook can increase the effective rotation capability of the rotating mechanism when starting, during rotation, braking, and holding in a set position.

[0057] See FIG. 6. The controller 114 communicates with at least one torque generating device 106, such as a gyroscope, gyro module / unit / device, control moment gyroscope (CMG), flywheel or other rotating device capable of applying torque to a load, one or more thrusters 108, and the motorized frictionless swivel 116. The controller 114 communicates with a power source or power source 132 that provides power to the one or more torque generating devices 106, the one or more thrusters 108 and their respective mounting elements 110, and the motorized frictionless swivel 116. The power source or power source 132 comprises one or more sources and may take the form of one or more batteries, diesel engines, gasoline engines, or hybrids thereof. In some embodiments, power is provided from a mains power source prior to the lift. Power may be maintained during the lift using a power source or power source 132 in the form of a small on-board battery or other power source to function with the controller 114, the torque generating device 106, the one or more thrusters 108 and their respective mounting elements 110, and the motorized frictionless swivel 116. It will be appreciated that the controller 114 may be in communication with one or more sensors 136 to obtain feedback, such as, but not limited to, one or more cameras, a microphone, one or more positioning sensors such as a real-time kinematic global positioning sensor (RTK GPS), an inertial measurement unit (IMU) such as a nine degrees of freedom (DOF) IMU, a light detection and ranging (LIDAR) unit, one or more stereo cameras, one or more cameras for recording images for purposes of photogrammetry and / or simultaneous positioning and mapping (SLAM), anemometers, and / or one or more output devices such as loudspeakers or light sources.

[0058] See Fig. 7. According to some embodiments, one or more thrusters 108 are rigidly coupled to one or more rotational devices, such as torque generating device 106, via a mounting element 110 in the form of a rigid arm. The arm can be telescopic or otherwise extendable, thereby providing an adjustable moment of one or more thrusters 108 about a pivot point 134. The gyroscope or gyro module 106 and one or more torque generating devices, such as one or more thrusters 108, work together, i.e., provide a rotational force in the same direction, to rotate and orient the payload 102 relative to the pivot point 134.

[0059] The pivot point 134 is frictionless or substantially frictionless due to the motorized swivel 116. The pivot point 134 contributes a negligible amount of counter-acting moment to the combined applied moment of the one or more torque generating devices 106 and the one or more thrusters 108.

[0060] The one or more torque generating devices 106 and the one or more thrusters 108 may operate simultaneously or in relay, whereby the one or more thrusters 108 are used for large angles of rotation and the one or more torque generating devices 106, such as gyroscopes or gyro modules, are then deployed for final fine or precise orientation of the load.

[0061] See Figure 8. According to some embodiments, where the at least one torque generating device 106 is in the form of one or more gyroscope or gyro modules, one or more thrusters 108 are used to provide an opposing rotational force, or torque, to the one or more gyroscope or gyro modules 106 while the flywheel of the one or more gyroscope or gyro modules 106 is sharply rotated back to the reset position. This opposing moment is carefully controlled / decelerated so that during the regenerative cycle, the net moment on the payload is zero, and therefore, zero rotation.

[0062] The directional control device 100 of the present invention may be operated in various operating modes. For example, all of the force / torque elements, i.e., one or more torque generating devices 106, one or more thrusters 108, and the motorized frictionless swivel 116, may be operated together, or a subset thereof may be operated in combination. In some operating modes, one or more thrusters 108 provide wind load offset compensation, and one or more torque generating devices 106 control inertia and fine positioning. In some operating modes, one or more thrusters 108 hold the load while resetting one or more torque generating devices 106 vertically for optimal control position. In some operating modes, in conjunction with a crane control system, the force / torque elements are combined to provide maximum position and rotation management. For example, the directional control device 100 of the present invention may make a load, such as a turbine blade, appear to rotate in a horizontal plane about a point that is not the center of gravity by combining the slew and luff motions of the crane boom with directional motions from one or more gyroscopes or gyro modules 106 and one or more thrusters 108.

[0063] According to another aspect or embodiment, the invention resides in a method of controlling a rotational direction of a load 104. With reference to FIG. 9 , according to some embodiments, such a method 200 includes, at 202, coupling a load 102 to a housing or framework 104. At 204, such a method includes attaching at least one torque generating device 106 to the housing or framework 104. At 206, such a method may include movably attaching one or more thrusters 108 to the housing or framework 104 directly or indirectly via one or more mounting elements 110 to vary a position of the one or more thrusters 108 from a center of the housing or framework 104. At 208, such a method may include controlling a rotational direction of the load 102 by controlling a ratio of rotational forces imparted to the load 102 from the at least one torque generating device 106 and the one or more thrusters via a controller 114 in communication with the at least one torque generating device 106, the one or more thrusters 108, and the one or more mounting elements 110. According to some embodiments, the method 200 may include, at 210, coupling the powered frictionless swivel 116 directly or indirectly to the housing or framework 104 and to one or more lines 118 from which the load 102 is suspended, and a controller 114 in communication with the powered frictionless swivel 116 controls the rate of rotational force imparted to the load 102 from the powered frictionless swivel 116. It is understood that the method 200 may not include all steps in which a source of rotational force is not used. For example, in some embodiments, the method does not include, at 206, movably attaching one or more thrusters 108 directly or indirectly to the housing or framework 104 via one or more mounting elements 110 where only the at least one torque generating device 106 and the powered frictionless swivel 116 are used.

[0064] 10-12. Another embodiment of the directional control device 100 of the present invention comprises a torque generating device 106 in the form of one or more resistance elements or mechanisms 138 that generate resistance in the presence of wind. The one or more resistance elements or mechanisms 138 are coupled to the load 102 and offset from the center of the housing or framework 104, e.g., toward one end of the load 102. The one or more resistance elements or mechanisms 138 are coupled in communication with the controller 114 and the power source 132. The one or more resistance elements or mechanisms 138 may comprise one or more slats or plates 140, e.g., having a rectangular profile. In some embodiments, the one or more slats or plates 140 are attached to, e.g., a rotatable rod or bar 142 driven by a motor, hydraulic, pneumatic arm, or other drive means, such that the orientation of the one or more resistance elements or mechanisms 138 is adjustable to vary the resistance, and therefore the torque, generated by the one or more resistance elements or mechanisms 138. The angle of incidence of one or more slats or plates 140 to the wind can be adjusted about the axis of the rod or bar 142 to change the drag coefficient of the one or more slats or plates 140 to the wind, and therefore the torque due to resistance at the center of the load 102. In some embodiments, the position of one or more resistance elements or mechanisms 138 from the center of the load 102 is adjustable or variable, for example, via one or more mounting elements 110 as described herein.

[0065] One or more resistive elements or mechanisms 138 may be used in place of or in addition to one or more thrusters 108 or one or more torque generating devices 106, such as a gyro module. For clarity, one or more thrusters 108 are omitted from FIGS. 10 and 11.

[0066] Thus, embodiments of the present invention address or at least ameliorate at least some of the problems mentioned above. For example, a directional control device 100 according to embodiments of the present invention includes one or more auxiliary sources of rotational force or torque for providing additional rotational control to that provided by a primary source of torque in the form of one or more torque generating devices 106, which is particularly useful for controlling the rotational movement of large and / or heavy loads. According to some embodiments, the one or more auxiliary sources of rotational force or torque are in the form of one or more resistance elements or mechanisms 138 and / or one or more thrusters 108, which provide a constant thrust, and thus a torque, that has an increasing effect with increasing distance from the center of gravity. The one or more thrusters 108 are movable via one or more mounting elements 110, which provide selectivity in the distance from the center of gravity and thus the moment provided by the one or more thrusters 108. According to some embodiments, the one or more auxiliary sources of rotational force or torque are in the form of an electrically powered frictionless swivel 116, which may be used in combination with or in place of the one or more thrusters 108. The various operating modes described herein provide further flexibility and adaptability in controlling the rotational orientation of a suspended load via directional control device 100.

[0067] As used herein, the terms "comprising," "including," or similar terms are intended to imply a non-exclusive inclusion, such that a device comprised of a list of elements does not include only those elements, but may well include other elements not listed.

[0068] Throughout this specification, the present invention is intended to be described without being limited to any one embodiment or collection of specific features. Those skilled in the art may appreciate variations from a particular embodiment that nevertheless fall within the scope of the present invention. For example, it is contemplated that one or more features from two or more embodiments described herein may be combined to form one or more further embodiments.

Claims

1. A direction control device that controls the rotational direction of a load suspended from the device, a housing or framework for coupling to said load; at least one torque generating device attached to the housing or framework or coupled to the load; one or more thrusters movably attached, directly or indirectly, to the housing or framework via one or more mounting elements to vary a position of the one or more thrusters from a center of the housing or framework; an electrically powered frictionless swivel coupled directly or indirectly to the housing or framework and coupled to one or more lines suspending the load; a controller in communication with the at least one torque generating device, the one or more thrusters, and their respective mounting elements, and the electric frictionless swivel, and configured to control a ratio of rotational forces imparted to the load from at least two of the at least one torque generating device, the one or more thrusters, and the electric frictionless swivel, thereby controlling a rotational orientation of the load; Equipped with the at least one torque generating device is configured to provide a primary source of rotational force to the load; An apparatus wherein the one or more thrusters and / or the powered frictionless swivel are configured to operate independently or in combination to provide auxiliary rotational force to the load.

2. 1. A method for controlling the orientation of a load, comprising: coupling a housing or framework to the load; attaching at least one torque generating device to said housing or framework or coupling at least one torque generating device to said load; movably mounting, directly or indirectly, one or more thrusters to the housing or framework via one or more mounting elements to vary a position of the one or more thrusters from a center of the housing or framework; connecting, directly or indirectly, an electric frictionless swivel to the housing or framework and to one or more lines suspending the load; controlling the rotational orientation of the load by controlling a ratio of rotational forces imparted to the load from at least two of the at least one torque generating device, the one or more thrusters, and the motorized frictionless swivel via a controller in communication with the at least one torque generating device, the one or more thrusters, and their respective mounting elements, and the motorized frictionless swivel; Inclusive of the at least one torque generating device providing a primary source of rotational force to the load; The method wherein the one or more thrusters and / or the powered frictionless swivel operate independently or in combination to provide auxiliary rotational force to the load.

3. 2. The apparatus of claim 1, wherein the at least one torque generating device is selected from a gyroscope, a gyro module (unit or device), a control moment gyroscope (CMG), a flywheel, a rotating mass (e.g., but not limited to, a mass of fluid moving around a closed gap), other rotating devices capable of imparting torque to the load, one or more resistance elements or mechanisms that create resistance in the presence of wind.

4. The device of claim 3 , wherein the position and / or orientation of the one or more resistance elements or mechanisms are adjustable to vary the resistance and, consequently, the torque generated by the one or more resistance elements or mechanisms.

5. 5. The apparatus of claim 3 or 4, wherein the one or more resistance elements or mechanisms are offset from a center of the housing or framework when coupled to the load.

6. 6. The apparatus of any one of claims 3 to 5, wherein the one or more resistive elements or mechanisms are communicatively coupled to the controller and power source.

7. An apparatus according to any one of claims 3 to 6, wherein the one or more resistance elements or mechanisms comprise one or more slats or plates.

8. 8. The apparatus of claim 7, wherein the one or more slats or plates are attached to a rotatable rod or bar driven by a drive means, and the orientation of the one or more resistance elements or mechanisms is adjustable to vary the resistance and, consequently, the torque generated by the one or more resistance elements or mechanisms.

9. 9. The apparatus of claim 8, wherein the angle of incidence of the one or more slats or plates to the wind can be adjusted about the axis of the rod or bar to vary the resistance coefficient of the one or more slats or plates to the wind, thereby varying the torque about the center of the load due to the resistance.

10. An apparatus as claimed in any one of claims 7 to 9, wherein the position of the one or more resistance elements or mechanisms from the centre of the load is adjustable or variable.

11. The electric frictionless swivel comprises a top or stator and a drive means, within the top or stator a bottom or rotor rotates on a thrust bearing relative to the top or stator, and the drive means rotates the bottom relative to the top. The device of any one of claims 1 and 3 to 10.

12. 12. The apparatus of claim 11, further comprising one or more sensors in communication with the controller for measuring rotational speeds of the top or stator and the bottom or rotor of the motorized frictionless swivel.

13. 13. The apparatus of claim 11 or 12, further comprising one or more sensors in communication with the controller for measuring a rotational speed of a crane boom.

14. The device described in any one of claims 1 and 3 to 13, wherein the electric frictionless swivel is used for one or more of the following purposes: lightening the load to initiate rotation of the load, lightening the load to maintain rotation of the load, braking, and holding the load in a set orientation.

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