Bucket Hoist Torque Control for Uniform Fill
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Bucket hoists often result in a partial fill of the load handling member due to manual operation variability, requiring skilled operators to maximize fill percentage while avoiding tipping, which is inefficient and prone to inconsistencies.
Innovation Solution
A control system with a two-axis master switch generating command signals for motor controllers to control the closing and holding motors, ensuring a consistent and uniform fill by regulating torque during the closing operation, allowing the load handling member to dig deeper into the material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual operation is used to control the bucket hoist, then operator flexibility is maintained, but fill consistency and uniformity deteriorate due to operator skill variability
Solution Approach 1:
The control system incorporates feedback mechanisms where the controller receives signals from sensors monitoring the load handling member position and motor status, automatically adjusting motor commands to maintain consistent fill levels across operations regardless of operator input variations
Solution Approach 2:
The patent replaces manual mechanical control with an automated electronic control system that uses a controller to manage motor operations, eliminating operator skill variability while maintaining operational flexibility through programmable control logic
2Stability of the object's composition
If the holding motor is held in position via brake or closed loop control, then positioning stability is improved, but digging efficiency and fill percentage worsen due to restricted downward motion
Solution Approach 1:
The control system dynamically adjusts the holding motor operation mode based on the operational phase: during digging, the motor allows controlled downward motion at reduced torque to enable the bucket to penetrate material; during positioning, it transitions to stable holding mode, optimizing both digging efficiency and positioning stability
3Productivity
If the load handling member is lowered too far during closing operation, then fill percentage improves, but the risk of tipping increases
Solution Approach 1:
The controller continuously monitors the position and operational status of the load handling member, using feedback signals to automatically adjust the lowering depth and closing speed, preventing excessive lowering that could cause tipping while maximizing fill percentage within safe operational limits
Data Source
AI summary
A control system for a bucket hoist includes a two-axis master switch configured to generate a first and a second command signal responsive to motion along each axis. Each command signal is provided to one of a pair of motor controllers configured to control one of a pair of motors. The two motors are controlled to raise/lower and open/close the load handling member. When the two-axis master switch is moved to the close position, the closing motor controller is commanded to control its respective motor to begin closing the load handling member. The holding motor controller is configured to generate a current to its respective motor to generate torque at a predefined level. The predefined level of torque is selected such that the load handling member lowers into the material in which it is digging as it is being closed.