3D Wire Flying Winch Safety Control

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Solution Overview

Problem

Existing three-dimensional wire flying systems lack effective multi-level safety measures to prevent harm caused by abnormalities in winches or their controlling software/hardware, leading to potential safety risks.

Innovation Solution

A three-dimensional wire flying system incorporating a winch with a drum unit, motor unit, brake module, limit switch, and servo-system, utilizing local and integrated safety devices to control the winch's operation based on predefined safety logic, ensuring safe operation by transmitting software and hardware-level signals to maintain the wire within preset length ranges and power limits, with an emergency switch for mechanical intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If a winch system is used to control wire length in 3D flying, then the system achieves automated wire management and positioning, but the system becomes vulnerable to safety hazards when winch abnormalities occur

Engineering Contradiction:

Improveautomated wire managementVSAvoidsafety against winch abnormalities

Core Design Contradiction:

Extent of automationVSReliability

Solution Approach 1:

The safety control system is segmented into three independent levels: software-based safety control, hardware-based safety control, and mechanical emergency stop. Each level operates independently and can trigger the others, ensuring that a failure at one level does not compromise overall system safety. This segmentation allows the system to maintain automated wire management while providing multiple layers of protection against winch abnormalities.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system implements beforehand cushioning by pre-configuring multiple safety mechanisms that activate automatically upon detecting abnormalities. The safety control unit continuously monitors winch parameters and is pre-programmed to trigger appropriate safety responses (software alerts, hardware interventions, or mechanical stops) before dangerous conditions fully develop, thereby cushioning against potential harm.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If multiple safety control levels are implemented, then safety against winch abnormalities is improved, but the system complexity increases

Engineering Contradiction:

Improvesafety controlVSAvoidcontrol system structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The three safety control levels (software, hardware, and mechanical) are merged into a unified safety architecture where they share common monitoring functions and coordinate their responses. The safety control unit integrates signals from all levels and coordinates actions across the board, reducing the need for separate independent systems while maintaining the benefits of multi-level protection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The safety control unit serves multiple functions: it monitors winch parameters, executes software-based safety logic, triggers hardware safety mechanisms, and coordinates mechanical emergency stops. This multi-functionality reduces the need for separate dedicated components for each safety level, thereby managing system complexity while providing comprehensive safety coverage.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Speed

If software-based safety control is used, then the system can respond quickly to abnormalities, but the system becomes vulnerable to software faults

Engineering Contradiction:

Improveresponse speedVSAvoidvulnerability to software faults

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The hardware-based safety control acts as an intermediary between the software control system and the mechanical winch. When the software detects an abnormality, it signals the hardware safety mechanism, which then independently triggers appropriate responses. This intermediary layer ensures that software faults cannot directly cause unsafe conditions, as the hardware layer provides independent verification and execution of safety functions.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system replaces purely software-based safety mechanisms with hardware-based safety controls that operate independently of software. Critical safety functions are implemented through dedicated hardware circuits and mechanical interlocks that do not depend on software correctness. This substitution ensures that even if software fails, the mechanical and hardware safety systems continue to provide protection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS9010733B2Three-dimensional wire flying system

Publication Date: 2015.04.21 KOREA INSTITUTE OF INDUSTRIAL TECHNOLOGY

AI summary

A three dimensional wire flying system includes a plurality of winches collectively hanging an object and a control unit for controlling the plurality of winches and the main safety device. Each of the plurality of winches includes a drum unit, a wire wound on the drum unit, a motor unit which provides power to the drum unit, a brake module which stops rotation of the drum unit, a limit switch which operates upon detecting a hardware limit state, and a servo-system. Each of the plurality of winches operates to move the object in a three dimensional space in three directions, including an up-down direction, a left-right direction and a forward-backward direction, and each winch provides a multi-level safety protection.