Boom Winch Control for Automatic Raising Without Wire Loosening
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Solution Overview
Problem
Existing boom devices require manual operation for storage and raising, which is labor-intensive and prone to wire loosening or breakage, and lacks versatility across different boom types due to unique geometry-dependent control requirements.
Innovation Solution
A controller that calculates displacement distance and wire speed based on detected derrick angle and stored specified values, allowing for automatic boom drive operations while maintaining constant extension/retraction speed or angular velocity, and incorporating tension sensors to adjust thresholds for safe operation, enabling common use across various boom devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operation is used for boom storage and raising, then the operator can control the process, but the operation efficiency is low and there is risk of wire loosening or excessive tension
Solution Approach 1:
The control device uses feedback from the length sensor to detect wire length and from the derrick angle sensor to detect boom angle, automatically adjusting winch drive to maintain ideal correspondence between wire length and boom angle, preventing wire loosening or excessive tension during automated operation
Solution Approach 2:
The system performs self-regulation by automatically controlling the winch drive unit based on sensor data and stored ideal correspondence, eliminating the need for manual operation while maintaining reliable wire tension control through automated feedback mechanisms
2Measurement precision
If a control device is designed for specific boom device geometry, then it can achieve precise control, but it cannot be commonly used for various boom devices
Solution Approach 1:
The control device stores multiple sets of ideal correspondence data corresponding to different boom device geometries and selects the appropriate set based on the actual boom device configuration, enabling a single control device to precisely control various types of boom devices
Solution Approach 2:
The system changes operational parameters by selecting different ideal correspondence sets from storage based on the specific boom device geometry, allowing precise control adaptation without redesigning the control device for each boom type
Data Source
AI summary
Provided is a controller with high versatility that can automatically store or raise a boom and can be commonly used for various boom devices. The controller generates a function based on a length of a boom and a distance from a derrick fulcrum of the boom to an engaging member stored in a memory, and a depression angle of the engaging member with respect to the fulcrum. Then, the controller substitutes a derrick angle of the boom detected by a derrick angle sensor into the generated function to calculate a displacement distance from a distal end of the boom to the engaging member. The controller rotates a winch while raising and lowering the boom between a lowered position and a raised position such that the calculated displacement distance is a distance corresponding to an unwinding length of a wire detected by a length sensor.