Automated Lifting Control for Heavy Load Positioning
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Solution Overview
Problem
Moving extremely heavy loads is complicated due to the large forces involved, often requiring disassembly and reassembly, and existing walking machines are tall and costly, with manual operation that is time-consuming and prone to loading inconsistencies.
Innovation Solution
A control system that automates the lifting and movement of heavy loads using multiple lift points, employing sensors and a computer to determine when each lifting device is loaded, allowing for simultaneous or incremental extension to evenly lift and move the load, reducing manual intervention and operational time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If walking machines use tall support load bearing frames to support loads, then the loads can be supported, but the height of the walking machines increases the overall cost of the transport system and limits which types of load bearing frames can be used
Solution Approach 1:
The load bearing frame is divided into multiple modular segments that can be configured in different arrangements. These segments work together to support the load without requiring a single tall continuous frame, thereby reducing overall height while maintaining load bearing capacity.
Solution Approach 2:
Instead of supporting the load vertically from below with tall frames, the system uses horizontally arranged modular frame segments that distribute support across multiple points and levels, effectively transitioning from a vertical height-dependent solution to a horizontal distribution solution.
2Reliability
If an operator manually controls each individual lift point, then loading inconsistencies can be addressed, but the operator must walk around the entire structure and control each lift point individually which adds substantial time to the stepping process
Solution Approach 1:
Sensors are installed at each lift point to automatically detect when the load has been lifted and to monitor loading conditions. This feedback system allows the operator to control all lift points from a single location without manually inspecting each point, maintaining loading consistency while dramatically reducing operational time.
Solution Approach 2:
The lifting system performs self-monitoring and self-adjustment through automated sensors that detect load status and provide real-time information to the control system, eliminating the need for manual inspection and adjustment at each lift point.
3Force
If multiple lifting devices are used to pick up a large load at multiple points, then the load can be lifted, but loading inconsistencies exist due to different ground compaction conditions at different lift points that require different lifting device extensions
Solution Approach 1:
The system incorporates dynamically adjustable lifting devices that can automatically modify their extension and lifting force based on real-time feedback from sensors at each lift point. This allows the system to adapt to varying ground conditions without requiring manual intervention for each location.
Solution Approach 2:
The lifting parameters such as extension length and lifting force are automatically adjusted based on sensor feedback regarding ground conditions and load status at each lift point, allowing the system to optimize performance across variable conditions without increasing operational complexity.
Data Source
AI summary
A control system detects a loaded state for a lifting device. The control system receives a current load value from a load sensor corresponding to a load on the lifting device and compares the current load value from a previously received load value to determine a change in load. The control system receives a current displacement value from a displacement sensor corresponding to a displacement of the lifting device and compares the current displacement value with a previously received displacement value to determine a change in displacement. The control system compares the change in load with the change in displacement to determine a current load slope. The lifting device in identified in a loaded state based on a comparison of the current load slope with a load slope threshold. The control system may stop extending the lifting device after reaching the loaded state and start extending all of the lifting devices in unison to lift the load off of a base surface after all of the lifting devices reach the loaded state.