Spring Counterbalance Cable Failure Detection
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Solution Overview
Problem
Spring force counterbalance mechanisms in load positioning systems face challenges in detecting failures of redundant elements, which can lead to unnoticed system failures and loss of load balance.
Innovation Solution
A redundant spring counterbalance mechanism with a cable system that includes a protrusion fixed to the cable, passing through a cable attachment with stops, and a sensor coupled to a pulley to detect anomalous rotation indicating cable breakage or failure, ensuring continuous load balance detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If redundancy is introduced in the spring counterbalance mechanism, then reliability is improved, but the ability to detect failures deteriorates
Solution Approach 1:
A sensor is coupled to the pulley to detect rotational position and provide feedback signals. The controller receives these feedback signals and determines cable integrity by analyzing whether the pulley rotation corresponds to expected load movement. This feedback mechanism enables detection of failures in redundant cable systems, resolving the contradiction between reliability improvement through redundancy and the ability to detect failures.
Solution Approach 2:
The patent replaces mechanical failure detection methods with electronic sensing and control systems. Instead of relying on mechanical indicators or manual inspection, electronic sensors detect pulley rotation and the controller processes this data to identify cable failures. This substitution enables effective monitoring of redundant systems without adding mechanical complexity.
2Reliability
If a single cable failure occurs in a redundant system, then load balance is maintained, but the failure goes unnoticed
Solution Approach 1:
The sensor continuously monitors pulley rotation and provides feedback to the controller. When one cable fails in the redundant system, the pulley rotation pattern changes, and the controller detects this anomaly through the feedback signal. This maintains load balance through redundancy while preventing loss of failure status information through continuous electronic monitoring.
Solution Approach 2:
The sensor and controller act as intermediaries between the mechanical cable system and the monitoring system. Instead of directly observing cable status, the system uses pulley rotation as an intermediary indicator. The sensor detects rotation changes caused by cable failures, and the controller interprets these changes to determine cable integrity, thereby preventing loss of failure information.
3Reliability
If redundant cable segments are used, then system reliability is improved, but device complexity increases
Solution Approach 1:
The patent merges the functions of multiple cables into a single pulley system. Instead of independently monitoring each redundant cable, the system combines their mechanical action through the pulley and uses a single sensor to detect the combined rotation. The controller then analyzes this unified signal to detect failures in either cable, reducing monitoring complexity while maintaining reliability benefits of redundancy.
Solution Approach 2:
The single sensor and controller system serves multiple functions: it monitors pulley rotation, detects cable failures, determines cable integrity, and provides feedback for load balance verification. This multi-functional approach allows the system to handle redundant cable configurations without proportionally increasing complexity, as one sensing system performs multiple monitoring tasks.
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 mechanism effectively detects cable breakage or failure, preventing unnoticed system failures and maintaining load balance by sensing anomalous pulley rotation, thus enhancing the reliability of the counterbalance system.
Implementation Method 1
A spring counterbalance mechanism balances a load with a spring
Implementation Method 2
In load positioning systems the effects of gravity on the load may be compensated for with a spring counterbalance
Implementation Method 3
A sensor coupled to the pulley senses rotation of the pulley allowing cable breakage to be detected by the anomalous rotation of the pulley
Data Source
AI summary
A spring counterbalance mechanism balances a load with a spring. A cable has a protrusion fixed to the cable midway between two ends of the cable. The two free ends of the cable are fixedly coupled to one of the load or the spring, and a cable attachment is coupled to the remaining member. The cable passes through the cable attachment such that the protrusion is captive in the cable attachment and is movable between two stops in the cable attachment. The cable forms two segments each of which couples the spring to the load. The two segments of the cable pass over a pulley. A sensor coupled to the pulley senses rotation of the pulley allowing cable breakage to be detected by the anomalous rotation of the pulley.