Cable Foul Sensor Actuator for Early Mis-wrap Detection
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Solution Overview
Problem
Existing cable foul sensors in cable winding applications fail to detect mis-wraps or fouls promptly, leading to operational delays and potential equipment damage due to delayed intervention after cable mis-alignment occurs.
Innovation Solution
A cable foul sensor with an actuator having two parts forming a passageway and at least one switch, which detects cable fouls by contact with the cable, allowing immediate interruption of the winding operation through actuation of the switch, enabling fast detection and prevention of cable mis-wraps or fouls during the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flapper plate with a sensing finger is used to detect cable fouling, then the sensor can detect cable mis-wraps, but the detection is delayed until the cable builds up to a height sufficient to trip the sensing finger
Solution Approach 1:
The actuator is positioned to detect cable fouling at an early stage, before the cable builds up to a height that would trip traditional sensing fingers. The actuator's strategic placement in the cable path allows preliminary detection of mis-wraps and fouling conditions, enabling early intervention and correction.
Solution Approach 2:
The actuator serves as an intermediary element between the cable and the switch mechanism. Rather than using a flapper plate that requires significant cable buildup to trigger, the actuator directly interacts with the cable position and transmits this information to the switch, providing more sensitive and timely detection.
2Reliability
If the sensing finger is positioned to detect cable buildup, then cable fouling can be detected, but the winding operation is not immediately stopped upon foul occurrence
Solution Approach 1:
The actuator is positioned to detect cable fouling at an early stage, before the cable builds up to a height that would trip traditional sensing fingers. The actuator's strategic placement in the cable path allows preliminary detection of mis-wraps and fouling conditions, enabling early intervention and correction.
Solution Approach 2:
The switch provides immediate feedback to the control system when the actuator detects cable fouling. This feedback mechanism enables real-time monitoring and immediate interruption of the winding operation, preventing further mis-alignment and allowing for quick correction, thereby maintaining both reliability and productivity.
3Reliability
If a flapper plate with extended sensing finger is used, then cable mis-wraps can be detected, but the device complexity increases compared to simpler sensor designs
Solution Approach 1:
The invention extracts the essential detection function from the complex flapper plate mechanism and implements it through a simpler actuator-switch arrangement. By removing unnecessary components like the extended flapper plate and focusing on the core detection principle, the design achieves reliable cable foul detection with reduced structural complexity.
Solution Approach 2:
The invention replaces the mechanical flapper plate system with a more compact actuator mechanism that directly responds to cable position changes. This substitution simplifies the mechanical structure while maintaining detection accuracy, reducing the number of moving parts and overall device complexity.
Data Source
AI summary
A cable foul sensor is provided for detecting a cable foul condition of a hoist or other cable reeling device. The cable foul condition may be sensed independently of the cable layer on a hoist cable drum. The cable foul sensor allows a cable foul condition to be detected before the cable mis-wrap caused by the foul condition extends outside of the envelope of the drum. The cable foul sensor may include an actuator having a first part and a second part disposed to form a passageway that receives a cable. At least one switch is disposed on the actuator. If the cable contacts at least one of the first part and the second part, the at least one of the first and the second part actuates the at least switch to control a winding operation of the cable.