Aerial Device Bonding Cable Integrity Monitoring System

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Solution Overview

Problem

Utility vehicle operators face time-consuming and hazardous manual tests for ensuring the integrity of electrical bonding cables in aerial devices, which can lead to exposure risks and equipment damage due to the lack of an automated monitoring system for conductive components and electrical bonding cables.

Innovation Solution

An automated system comprising an electronic control module with a microprocessor, memory, and feedback wires to monitor the voltage on electrical bonding cables, determining their condition and notifying operators of any issues, with configurations for series or parallel connections to assess collective or individual cable resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual continuity test is performed using digital multi-meter, then bonding condition can be detected, but operator exposure time to hazard increases and operation time is consumed

Engineering Contradiction:

Improvebonding condition detectionVSAvoidoperator exposure time and operation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system enables self-service by allowing the aerial device to automatically monitor its own bonding conditions through integrated sensors and control circuits, eliminating the need for operator intervention in manual testing while maintaining continuous safety monitoring

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical testing procedures with automated electronic monitoring systems that continuously measure bonding resistance and electrical continuity, substituting operator-performed manual tests with automatic electronic detection circuits

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If manual continuity test is performed, then bonding integrity can be verified, but operation complexity increases and productivity decreases

Engineering Contradiction:

Improvebonding integrity verificationVSAvoidoperation efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system implements continuous monitoring of bonding conditions throughout operation, eliminating the need for intermittent manual testing and maintaining constant safety verification without interrupting workflow or reducing productivity

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The aerial device performs self-verification of bonding integrity through automatic sensing and evaluation circuits that continuously assess bonding resistance and alert operators only when threshold violations occur, eliminating time-consuming manual testing

Inventive Principle:

Principle #25Self-service

3Object-affected harmful factors

If soak test is performed without personnel on platform, then operator exposure to hazard is limited, but property damage can still occur and automation is lacking

Engineering Contradiction:

Improveoperator exposure to hazardVSAvoidtesting automation

Core Design Contradiction:

Object-affected harmful factorsVSExtent of automation

Solution Approach 1:

The patent replaces manual soak testing procedures with automated electronic monitoring systems that use sensors and control circuits to detect bonding failures, substituting human-operated mechanical testing with automatic electronic detection

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system implements continuous feedback monitoring of bonding resistance through sensors that provide real-time data to control circuits, enabling automatic detection and alerting without requiring operator presence or manual intervention during testing

Inventive Principle:

Principle #23Feedback

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system provides a safer, more efficient method for monitoring electrical bonding cables, reducing operator exposure and equipment damage by automatically detecting damaged or broken cables and disabling unsafe operations, thus ensuring reliable electrical bonding and preventing electrical shocks.

Implementation Method 1

monitors the voltage on the feedback wire, and based on the monitored voltage, determines a bonding state of the conductive components and the electrical bonding cables

Methodology Applied

Scientific EffectElectrical Resistance: Electrical Resistance

Data Source

PatentUS10908228B1Broken boom tip bonding detection

Publication Date: 2021.02.02 ALTEC INDS

AI summary

A device for detecting the condition of electrical bonding of a plurality of conductive components of an aerial device, the aerial device comprising a plurality of electrical bonding cables, a control module, a gradient control device, a feedback wire to carry an input signal from the conductive components to the control module, and a power source. The device uses the input signal to determine the condition of the electrical bonding of the conductive components including the condition of the electrical bonding cables and connections therebetween and is configured to notify an operator if an unacceptable condition is determined based on a predetermined acceptance standard.