Automated Load Bar Center of Gravity Positioning
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Solution Overview
Problem
Conventional load control systems for overhead cranes are inefficient in adjusting to changing centers of gravity during aircraft module assembly, requiring extensive time and multiple load bars, and lack adequate safety features for high-value components.
Innovation Solution
An automated adjusting load bar system utilizing electronic tilt sensors, compact industrial computers, direct current pulse width modulation motor drives, and custom software with a graphical user interface, along with a mechanical drive unit and redundant control systems, to accurately position the load bar relative to the center of gravity and ensure multi-level safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional load bars with turnbuckles are used to adjust the load bar for center of gravity positioning, then the component can be lifted correctly, but the adjustment time consumes one hour or more and the total move time exceeds three hours
Solution Approach 1:
The patent replaces the manual mechanical turnbuckle adjustment system with an automated electro-mechanical positioning system. The load bar positioning device uses motorized actuators controlled by a processor to automatically adjust the load bar position based on center of gravity calculations, eliminating the need for manual turnbuckle adjustments and reducing positioning time from over one hour to minutes.
Solution Approach 2:
The system performs self-positioning by automatically calculating the center of gravity based on sensor data and autonomously adjusting the load bar position without requiring manual intervention. The processor receives input from sensors, computes the optimal position, and controls the actuators to achieve proper alignment, making the system self-sufficient in the positioning task.
2Adaptability or versatility
If separate spreader bar assemblies are required for each component version to account for different centers of gravity, then each module can be extracted properly, but the equipment cost and floor space requirements increase significantly
Solution Approach 1:
The patent creates a universal load bar positioning device that can accommodate multiple component versions with different centers of gravity. The system uses sensors to detect the specific component configuration and automatically calculates the appropriate load bar position, allowing a single device to replace multiple version-specific spreader bar assemblies and reducing the total number of load bars needed from eighteen to one.
Solution Approach 2:
The system dynamically adapts to different component versions by using sensors to detect the current configuration and automatically adjusting the load bar position in real-time. This dynamic adjustment capability allows the same physical device to serve multiple functions across different component variants, eliminating the need for static, version-specific hardware configurations.
3Extent of automation
If automated centering systems with pendulum or gimbal-type sensor devices are used, then centering can be automated, but significant deviation in leveling is required prior to centering and redundant control systems are not provided
Solution Approach 1:
The patent implements a feedback-based control system where sensors continuously monitor the load bar position and component orientation, and the processor uses this feedback to make real-time adjustments. The system provides visual feedback through lights indicating when proper positioning is achieved, and incorporates redundant sensor arrays that cross-validate measurements to ensure reliability and provide multi-level safety control.
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
This system significantly reduces the time required to adjust and move components by accurately positioning the load bar over the center of gravity, eliminates the need for multiple load bars, and provides enhanced safety features, including automatic emergency stops and manual override, to ensure stable and precise lifting and transport of high-value modules.
Implementation Method 1
electronic tilt sensors
Implementation Method 2
direct current pulse width modulation motor drives
Implementation Method 3
linear screw drive actuators
Data Source
Figure 1
Figure 2
Figure 3a
AI summary
An apparatus, program product, and related methods for gravity stabilizing a suspended load are provided. The apparatus includes an center of gravity stabilized automated adjusting load bar in communication with a mobile cart which allows an operator to enable automated stabilization of a load. The adjusting load bar includes redundant first and second control and drive systems. A third control system can both monitor sensed data and the movement commands of first and second control systems, and can monitor the resulting physical movements. If a movement command and the resulting movement does not match or if there is an out of tolerance mismatch between movement commands of the first and the second control systems, the third control system can automatically detect this condition and shift into an emergency stop condition.