A dual-factor safety system that minimizes various risks that may arise during operation by monitoring both angle and weight

Abstract

The invention relates to a safety system that minimizes various risks that may arise during operation by monitoring both angle and weight and enables operators to make safe decisions, as well as a load-indicator-equipped inclinometer that provides data to this system.

Description

[0001] A DUAL-FACTOR SAFETY SYSTEM THAT MINIMIZES VARIOUS RISKS THAT MAY ARISE DURING OPERATION BY MONITORING BOTH ANGLE AND WEIGHT

[0002] TECHNICAL FIELD

[0003] The invention relates to a safety system that minimizes various risks that may arise during operation by monitoring both angle and weight and enables operators to make safe decisions, as well as a load-indicator-equipped inclinometer that provides data to this system.

[0004] BACKGROUND

[0005] Ensuring the safe operation of lifting systems is critically important, especially in heavy load handling and processing applications. The weight of the load being lifted and its angle relative to the lifting system are among the most crucial factors for safe operations. In this context, indicators and angle limit sensors are used as products designed to carry out safety functions. These components serve as essential elements for the safe management and control of loads.

[0006] Indicators provide operators with real-time information about the current load weight and prevent lifting operations from exceeding predefined limit values by utilizing integrated relays. This functionality allows for the early detection of potential risks, ensuring safe operation.

[0007] Angle limit sensors provide operators with real-time information about the angle between the load and the crane cable relative to the vertical plane. If the load exceeds a predefined inclination angle, the system ensures safety by stopping the lifting operation using an integrated relay, similar to indicators. This protection prevents potential damage that may occur during lifting operations.

[0008] Such structures minimize the risk of human error and provide a fast and effective response mechanism in emergency situations.

[0009] The safety measures in the known state of the art, which involve the separate use of indicators and angle limit sensors, overlook an important aspect in heavy load transportation and lifting applications. Since indicators operate solely based on weight values, they respond independently of the load's position, specifically its angle relative to the system. This situation can create safety risks when lifting a load on an incline or when the operator disregards the angle. On the other hand, angle limit sensors only monitor the angle and ignore the weight factor. In other words, even if the load weight changes, the system will respond solely based on the angle limit. This creates a disadvantage in ensuring safe operations, especially on mobile cranes and other moving platforms, as both devices operate based on a single factor. Since the load’s weight distribution changes as the lifting angle varies, a system that makes decisions based solely on either angle or weight may be insufficient.

[0010] Evaluating the lifting angle and the weight of the load within a unified decisionmaking mechanism enhances safety measures to a higher level, ensuring more accurate output results.

[0011] AIM OF THE INVENTION

[0012] The relationship between angle and weight is crucial for the proper management of dynamic forces, especially during heavy load transportation. In lifting operations, when a load is positioned at a certain angle, the weight vector is divided into vertical and horizontal components. In this case, the lifting system must make decisions not only based on weight limits but also on angular deviations. This integrated structure provides more precise and secure results compared to evaluations based solely on angular or weight values.

[0013] The weight (W) of an object is a force generated by gravity and acts vertically downward. If a load is lifted at a perfectly vertical angle, the entire weight is exerted vertically on the lifting system. However, when the object is lifted at a certain angle, the weight force is divided into two components:

[0014] • Vertical Component (W * cos 0): The portion of the weight force that is carried vertically by the system.

[0015] • Horizontal Component (W * sin 0): The force pulling the object sideways due to the inclination, which acts as a horizontal load on the lifting system.

[0016] Due to the influence of these components, the effective weight decreases when the load is positioned at an angle. For example, if an object is lifted at a 45-degree inclination, the vertical weight component decreases to approximately 70.7% of the object's total weight {cos(45) « 0.707}. However, the horizontal component alters the horizontal force balance within the system, which can create an instability risk, particularly in lifting systems such as cranes, potentially leading to tipping hazards.

[0017] An example of a pneumatic conveying application is provided at the following link: https: / / www.teknoconvey.com / blog / 2017 / 01 / 23 / pnomatik-tasima-sistemleri- degiskenler /

[0018] An example of an article can be accessed at the following link: https: / / tez.yok. gov.tr / UlusalTezMerkezi / tezDetay.jsp?id=k6MleHCk81 EV1Aq58NU0N A&no=kZGFjDYzQAWbTsPLtByt4Q

[0019] As the weight and angle of inclined loads change, the dynamic effects exerted by the load on the lifting system also vary. For instance, if the load is not lifted in a perfectly vertical position, the horizontal component exerts a lateral pulling force on the lifting system. An increase in this force may lead to load instability and result in a hazardous lifting operation. As the angle increases, the horizontal force component grows, causing shifts in the system's center of gravity. This displacement necessitates the establishment of a stable structure to prevent the lifting system from tipping over. Particularly in mobile cranes, monitoring the balance between angle and weight is crucial for accurately defining safety limits.

[0020] When considering the vectorial distribution of forces, "net force" calculations are performed in inclined load lifting. The net force is defined as the resultant of the vertical and horizontal components:

[0021] As the angle increases, this force causes greater weight loss in the horizontal direction, leading to an imbalanced load on the system. This effect of angle and weight can push the load beyond safe lifting limits, creating a risk in handling operations.

[0022] A dual-factor safety system that simultaneously evaluates two separate measurement criteria is a critical approach to ensuring high safety and precision in lifting and handling operations. The system subject to our invention monitors both angle and weight, minimizing various risks that may arise during operations and enabling operators to make safe decisions. This safety system does not rely solely on weight or angle but considers the combination of these two variables, resulting in a much more effective safety mechanism.

[0023] The dual-factor safety system subject to the invention evaluates weight and angle data together, providing more precise safety results compared to systems that operate based on a single factor. For instance, if there is an imbalance between the load’s weight and lifting angle, the system detects this condition and takes appropriate safety measures. This process establishes a more sensitive safety mechanism compared to monitoring only angle or weight limits individually.

[0024] In inclined lifting operations, where the weight components are distributed vertically and horizontally, the dual-factor safety system takes into account the angle at which the load is positioned and the resulting weight distribution. This system ensures safe operation, particularly in applications with a high risk of instability, such as mobile cranes, by adjusting safety limits based on the angular position of the load.

[0025] The core principle of the dual-factor safety system is a decision-making algorithm that integrates both weight and angle. For example, when the load exceeds a certain angle, the weight limit is reduced, or the angular safety limit is set at a more sensitive threshold. This algorithm continuously monitors both factors simultaneously and automatically determines the most appropriate safety decision without requiring manual adjustments from the operator.

[0026] Mobile cranes, especially when operating on uneven or sloped terrain, can fully benefit from the advantages of the dual-factor safety system. For instance, if the hoisting rope is positioned far from the crane or at a specific incline, the system simultaneously evaluates both weight and angle. By considering the horizontal force component and the risk of tipping, the system detects when the load exceeds a certain weight and angular limit, automatically halting the lifting process. This provides a fast and reliable safety solution by preventing operator errors or delays in emergency situations.

[0027] LIST OF FIGURES

[0028] Figure 1 : System Data Generation Algorithm

[0029] Figure 2: Sensor Fusion Flowchart

[0030] DETAILED DESCRIPTION OF THE INVENTION

[0031] The invention relates to a safety system that monitors both angle and weight to minimize various risks that may arise during operation and enables operators to make safe decisions, as well as a load-indicating inclinometer that provides data to this system. The core component of the system is a load-indicating inclinometer, which is mounted on crane ropes to measure both the load being lifted and its angle relative to the vertical axis, supplying data to the dual-factor safety system. Another component of the system is a controller that processes measurement data received from the load-indicating inclinometer and generates a signal to be detected by the control unit of the industrial machine in which the system is used. The controller can be a processor. Within the system, the controller continuously receives two primary inputs from the load-indicating inclinometer (weight sensor):

[0032] • Weight Sensor: Measures the real-time weight of the load and transmits it to the controller.

[0033] • Angle Sensor: Monitors the lifting angle of the load relative to the vertical axis and sends inclination data to the controller.

[0034] The data received from the load-indicating inclinometer (weight sensor) is processed by an algorithm within the software on the controller (Figure 1).

[0035] The methods and technologies used in the dual-factor safety system of the invention integrate both weight and angle data to support the decision-making process through a combination of algorithms and hardware. A sensor fusion algorithm has been adopted for this system.

[0036] Sensor fusion enables the combination of data from different sensors to obtain more reliable and meaningful results. In the dual-factor safety system, the fusion of data from angle and weight sensors allows real-time monitoring and evaluation of these two factors, ensuring the safest and most accurate decisions. In this algorithm, weight and angle data are compared against predefined threshold values, and the relationship between these two data points is analyzed. For example:

[0037] • If the angle exceeds a certain threshold, the weight limit is updated accordingly.

[0038] • If both data exceed the safe limits, an emergency stop decision is triggered.

[0039] Through the mentioned sensor fusion, both angle and weight information are considered simultaneously to determine whether the system should operate. The workflow diagram provided in Figure 2 summarizes the system's operational logic.

[0040] Evaluating angle and weight measurements together is essential to enhance safety standards and establish a more precise control mechanism. A system based on a single factor alone cannot adequately assess the risks that may arise during lifting operations. For instance, even if a load remains within weight limits, the lifting system may lose balance if the load is carried at a specific angle. This situation can pose a danger to both the operator and surrounding equipment. Processing angle and weight data together through an algorithm minimizes such risks and ensures that the system operates more safely. The processing of this data by a controller enables security decisions to be made accurately and swiftly. The inclination data from the angle sensor and the weight data from the load indicator (weight sensor) are combined and normalized on an electronic board. This ensures that data with different units can be compared effectively. The controller analyzes this combined data to assess whether the system is operating within safe limits. This structure utilizes both sensors simultaneously during lifting operations, distinguishing itself from existing systems and introducing a new safety standard.

[0041] One of the functions of the controller is the angle limiting function. When the load exceeds a certain angle, the system automatically reduces the weight limit. This process prevents imbalances that may occur when transporting loads in inclined positions and reduces the risk of operator error. For example, when the inclination of the load increases while the crane is operating, the controller dynamically readjusts the weight limits and maintains safe operating limits. This feature ensures that the system not only evaluates angular information but also uses it to take appropriate safety actions.

[0042] One of the most critical safety mechanisms of the system is its ability to automatically stop the lifting operation when limit values are exceeded. The controller continuously monitors both angle and weight data, and when these values exceed safe thresholds, it activates a relay through a generated signal to stop the lifting motors. This automatic stopping process prevents both the system and the load from being damaged. Ensuring safety without the need for immediate operator intervention allows the system to take necessary safety measures independently, minimizing the risk of human error.

[0043] The controller filters the data received from the sensors, which have been merged and normalized through the electronic board. Filtering the sensor data is a crucial process to ensure safe and accurate results. The integrated components used in the load indicator and angle sensor provide high-precision data. However, due to environmental influences and system dynamics, this data is not suitable for direct processing in its raw form. In addition, there may be instances of erroneous data transmission. Therefore, filtering is necessary to make the data both meaningful and reliable. The merged and normalized analog signals received from the load indicator are converted into digital data by the controller. During this process, environmental electrical noise or mechanical vibrations may cause deviations in the measurements. In particular, high-precision converter integrated circuits are sensitive to such small fluctuations. Therefore, raw data is stabilized using digital filtering algorithms. The load indicator, which continuously measures weight, may transmit fluctuating and difficult- to-interpret values due to the rapid data flow. This situation, especially in industrial applications, makes it difficult for users to clearly interpret the measurement results. Therefore, the filtering methods applied in the load indicator are designed to minimize temporary errors in weight measurements and to provide stable data. The filtering process involves adding the measured weight values to an array at regular intervals over a specific period of time and processing this array through various operations to produce an average value. First, the frequency at which the weight data is added to the array is defined through the device's "Delay" setting. This setting determines the time interval between measurements and allows the user to choose between faster or more stable measurements. For example, if a delay of 150 ms is selected, the device adds a new weight value to the array every 150 ms. The average is then calculated accordingly. The total number of data entries to be added to the array is controlled by the “Sensitivity” setting. Through this setting, the user determines how many elements the array will contain. The number of elements in the array directly affects the total duration over which the weight data is collected and the sensitivity of the device. An array containing more elements can increase measurement accuracy but may slow down the response time. For example, an array with 10 elements stores the last 10 measurement results and performs analysis based on these values. All of the aforementioned settings related to the load indicator can be configured via the controller. This is made possible through an interface, which is a standard method of accessing all hardware components.

[0044] Once the data is collected from the load indicator, the filtering phase begins to ensure that the weight values are displayed more steadily. At this stage, the *Filter* setting becomes active. The values in the array are sorted in order of magnitude, and for the purpose of averaging, the central values are selected based on the defined filter setting. For instance, if the filter value is set to “4,” the 4 central elements of the array are considered, and their arithmetic mean is calculated and transmitted as the output data. This process reduces the effects of environmental noise or sudden measurement fluctuations.

[0045] Thanks to the algorithm steps described above, the load indicator presents weight measurements in a more stable and reliable manner. For example, when a 150 ms delay time, a 10-element array, and a 4-element filter setting are used, the indicator adds a new data point every 150 ms to build an array, sorts this array, and calculates the average from the selected values to generate a stable weight value. This process not only helps operators make more accurate decisions but also prevents measurement errors in industrial processes. An example measurement result is shown in the table below.

[0046] Weight Data Continuously Read

[0047] Adding Elements to Array Based on

[0048] 1520 SENSIT Value (10)

[0049] Averaging Elements hown 1521

[0050] Another component of the system, the angle sensor, provides angular motion and inclination information by combining data from an accelerometer and a gyroscope. First, to calculate the angle, data from the gyroscope and accelerometer are collected. These sensors read high and low values separately for each axis. For example, for the X-axis, "GyroX High" and "GyroX Low" values are read and combined to calculate the amount of rotation on the axis. Similarly, accelerometer data is used to determine the accelerations on the X, Y, and Z axes. Once the raw data is collected, the angle values are calculated. Using the accelerometer data, the angles are first found in radians and then converted into degrees. The gyroscope data, on the other hand, is used to measure the change in angle over time. Subsequently, these two different sensor data sets are combined in a way that complements each other. In this process, a method called "Complementary Filtering" is employed. Complementary filtering combines the long-term stability of the gyroscope data with the short-term accuracy of the accelerometer data, thereby enabling the calculation of a final, reliable angle value. For example, during the calculation process, 98% weighting is assigned to the gyroscope data and 2% to the accelerometer data. After this filtering process, the resulting angle values are monitored with threshold limitations. The system, via the controller, evaluates whether the measured angle remains within a predefined range. If the angle exceeds the specified maximum limit, safety measures are activated accordingly. In addition, the angle values are processed separately as positive and negative. For example, as long as negative angle values do not exceed a certain tolerance threshold, they can be converted into positive values and displayed accordingly. The angle data is calculated and updated at 150 ms intervals. This method reduces fluctuations and provides more stable data. The filtering applied in the angle sensor hardware increases the accuracy of the sensor data and ensures the system operates reliably. As a result, users can clearly and consistently monitor the angle and benefit from the system’s safety features.

[0051] As previously mentioned, the sensor fusion combines both the weight data from the load indicator and the angular data from the angle sensor to form a dual-factor safety system. This integration is made possible by normalizing the raw data and creating a unified data model. In this way, the data from both sensors is utilized within a decision-making algorithm that evaluates safety limits and makes operational decisions.

[0052] The accurate functioning of the sensors used in the load indicator and angle sensor hardware depends on the application of algorithms that filter out noise and fluctuations. Following this, the system is based on a sensor fusion approach that combines both data sources to enhance safety and operational precision.

[0053] The controller algorithm is at the core of these processes. The algorithm processes the angle and weight data by filtering and normalizing the values and evaluating them against predefined safety limits. It considers sudden variations in the incoming data over a specific time period and makes decisions based solely on meaningful data. The system compares the angle and weight values to determine whether the lifting operation is safe. If both measurements indicate a risky condition, the algorithm generates a signal via the controller to alert the operator and halt the lifting operation. This process enables continuous monitoring of safety thresholds and allows real-time decision-making.

[0054] The combined processing of angle and weight data enables the system to quickly detect unbalanced loads and angular deviations. This integrated structure provides a dual-factor approach in terms of safety.

Claims

CLAIMS1 . A dual-factor safety system for cranes, which minimizes various risks that may occur during operation by monitoring both the angle and the weight of the lifted load, characterized in that it comprising a load indicator-based angle sensor, positioned on a crane rope, configured to measure both the load being lifted and the lifting angle relative to the vertical axis, wherein the load indicator-based angle sensor further comprising a weight sensor for measuring the instantaneous weight of the load and an angle sensor for monitoring the lifting angle relative to the vertical axis and transmitting tilt data to an electronic board; an electronic board configured to combine and normalize the weight and angle data received from the load indicator-based angle sensor; and a controller configured to process the weight and angle data from the load indicator-based angle sensor, which have been normalized via the electronic board, by converting them into digital data, filtering the data, comparing them with predefined threshold values, and analyzing the relationship between the two data sets, and generating a signal to be interpreted by the control unit of the industrial machine in which the system is used, such that, if the angle exceeds a certain value, the weight limit is updated accordingly, or, if both values fall outside of safe limits, to issue an emergency stop signal.

2. The dual-factor safety system according to claim 1 , characterized in that the controller comprises an interface configured to allow adjustment of delay, sensitivity, and filter settings, and is further configured to perform filtering by adding the data received from the load indicator and the angle sensor into an array at regular intervals over a certain period and calculating the average of the values in the array.

Images