Cable Angle Sensor for Bridge Crane Inertia Reduction
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Solution Overview
Problem
Overhead bridge cranes face inefficiencies due to significant inertia added by balancing systems, especially when manually operated, and require powerful actuators for vertical motion, which can lead to bouncy displacement and increased friction, hindering smooth movement of payloads.
Innovation Solution
A movement system comprising a bridge crane, trolley, and a movement device with a cable angle sensor that measures angular displacement of curved elements, allowing the cable to pivot and control the movement of the payload along X and Y axes, reducing the need for manual operation and minimizing inertia by maintaining the cable vertical.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If balancing systems based on counterweights are used to compensate for payload weight, then vertical motion is facilitated, but significant inertia is added to the system which hinders horizontal motion
Solution Approach 1:
The patent uses a cable-based counterbalancing mechanism where the cable passes through curved guide elements that pivot to maintain cable verticality. The counterweight system compensates for payload weight during vertical motion while the cable angle sensors and curved guide elements minimize horizontal inertia by keeping the cable aligned vertically during horizontal movements.
2Ease of operation
If pressurized air systems are used for balancing, then vertical motion is assisted, but displacement becomes unsmooth and bouncy due to friction in cylinders
Solution Approach 1:
The patent replaces traditional pressurized air cylinder mechanisms with a cable-based system that uses curved guide elements and angle sensors. This substitution eliminates the friction and bounce issues inherent in pneumatic cylinders while maintaining the ability to assist vertical motion through the cable tensioning mechanism.
3Power
If powerful actuators are attached to the trolley or bridge for vertical motion, then vertical lifting capability is achieved, but the system complexity and friction increase
Solution Approach 1:
The patent extracts the vertical lifting function from the moving trolley/bridge actuators and implements it through a separate cable-based counterbalancing system. The cable passes through curved guide elements that remain attached to the bridge structure, separating the vertical support function from the horizontal positioning mechanisms and reducing overall system complexity.
4Device complexity
If manual operation is used for horizontal axes, then device complexity is reduced, but operator effort increases due to lack of power assistance
Solution Approach 1:
The patent applies counterbalancing principles to reduce the effort required for manual operation. The cable system with curved guide elements creates mechanical advantage that reduces the force needed by the operator to move the trolley horizontally, while maintaining a relatively simple mechanical structure without full motorization.
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 system enhances the efficiency and smoothness of payload movement by reducing the operator's manual effort, minimizing inertia, and ensuring precise control, allowing for cooperative and autonomous motion while reducing sway and oscillations.
Implementation Method 1
The cable angle sensor is configured to measure the angular displacement of the cable
Implementation Method 2
The first curved element is configured to pivot about a first axis and the second curved element is configured to pivot about a second axis
Implementation Method 3
The cable is configured to pivot relative to the attachment portion such that the cable angularly displaces at least one of the first and second curved elements
Data Source
AI summary
A movement system includes a bridge crane, a trolley, and a movement device. The movement device includes an attachment portion, a plurality of housings, first and second curved elements, a cable, and a cable angle sensor. The curved elements are pivotally attached to housings and perpendicularly overlap with one another such that a first slot defined in the first curved element is perpendicular to a second slot defined in the second curved element. The first curved element is pivotable about a first axis and the second curved element is configured to pivot about a second axis. The cable extends from the attachment portion and through each of the slots. The cable is pivotable to angularly displace at least one of the curved elements about a respective axis. The cable angle sensor is configured to measure the angular displacement of the at least one of the first and second curved elements.