Automatic Leveling Device for Crane Load Orientation

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Solution Overview

Problem

In industrial and construction settings, cranes face challenges in lifting and transporting heavy loads due to the time-consuming process of balancing loads and potential weight shifts during transport, which can lead to safety issues for nearby workers.

Innovation Solution

An automatic leveling device comprising a motor, linear actuator, and slideable bail assembly, controlled by a sensor and controller assembly that adjusts the load's orientation to maintain a predetermined position, either horizontal or angled, using AC or DC power sources and programmable logic controllers, with features for setting angular ranges and inclinations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual load balancing is used during crane operations, then operators can adjust load position, but the process is time-consuming and labor-intensive

Engineering Contradiction:

Improveload balancing speedVSAvoidtime for load balancing

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical load balancing operations with an automated electronic control system. Sensors detect load orientation and weight distribution, the controller processes this data, and automatically adjusts the bail assembly position to balance the load, eliminating time-consuming manual intervention while maintaining precise control

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The load balancing system operates autonomously by continuously monitoring load conditions through sensors and automatically adjusting the bail assembly position without human intervention. The system serves itself by detecting imbalances and correcting them through automated motor-driven adjustments, significantly reducing operational time

Inventive Principle:

Principle #25Self-service

2Reliability

If load balancing is performed manually, then some level of control is achieved, but weight shifts during transport can still occur causing safety issues

Engineering Contradiction:

Improveload stabilityVSAvoidweight shift during transport

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The system continuously monitors load orientation and weight distribution through sensors during the entire transport process. This real-time feedback allows the controller to detect any weight shifts or imbalances that occur during transport and automatically adjust the bail assembly position to correct these changes, maintaining load stability and preventing safety issues

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs preliminary load balancing adjustments before transport begins and continues to make corrective adjustments throughout the transport process. By proactively detecting and correcting potential weight shifts before they become hazardous, the system prevents safety issues rather than merely responding to them

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If an automatic leveling device is implemented, then load orientation is maintained automatically, but device complexity increases

Engineering Contradiction:

Improveautomatic load levelingVSAvoidsystem components

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The controller assembly serves multiple functions: it receives signals from orientation sensors, processes load balance data, controls motor operations for bail assembly adjustment, and monitors system status. By consolidating these diverse functions into a single multi-functional controller, the system achieves automatic load leveling while minimizing the number of separate components and reducing overall system complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 automatic leveling device ensures stable load transport by maintaining the desired orientation of the load, reducing the risk of imbalance and enhancing safety by automatically adjusting the bail assembly to keep the load surface within specified angular ranges, thus improving the efficiency and safety of crane operations.

Implementation Method 1

The controller assembly includes an inclination sensor that detects the orientation of the load surface

Methodology Applied

Scientific EffectInclination sensor:

Implementation Method 2

A motor operates the linear actuator to move the bail assembly away from or towards the motor

Methodology Applied

Scientific EffectLinear actuator:

Data Source

PatentUS10077168B2Automatic leveling device with adjustable orientation setting

Publication Date: 2018.09.18 THE CALDWELL GROUP

AI summary

An automatic leveling device includes a motor mounted onto a frame, a linear actuator coupled to the motor, and a slideable bail assembly coupled to the linear actuator. The bail assembly is attached to the frame. The frame is configured to attach to a lifting beam, which is attached to a load surface. A controller assembly has a sensor configured to determine an orientation of the load surface when the load is suspended. The controller assembly is configured to automatically control the motor in order to position the slideable bail assembly such that the load is suspended in a predetermined orientation.