Counterweight Hoist Digital Brake Control for Runaway Prevention
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Solution Overview
Problem
Manually operated counterweight hoists in theaters lack modern safety features and integration with digital rigging control systems, posing risks due to unbalanced loads and runaway conditions.
Innovation Solution
Incorporating a digital controller with sensors and actuators into manually operated counterweight hoists to monitor load and speed, activating brakes automatically when thresholds are exceeded, and integrating with a digital rigging control system for centralized management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manually operated counterweight hoists are used without digital control systems, then device complexity is reduced and ease of manufacture is improved, but safety is worsened due to lack of modern safety features and integration with digital rigging control systems
Solution Approach 1:
The patent replaces manual mechanical operation with an automated digital control system. The controller receives input signals, processes them digitally, and automatically actuates the brake mechanism, substituting the purely mechanical manual operation with an electromechanical control system that enhances safety through digital monitoring and automated response.
Solution Approach 2:
The system implements feedback by having the sensor continuously monitor arbor speed and transmit this information to the controller. The controller processes this feedback signal and automatically adjusts the brake actuator to maintain safe operating conditions, creating a closed-loop control system that responds to actual system state.
2Reliability
If sensors and controllers are added to manually operated hoists, then safety is improved through automated brake activation, but device complexity increases
Solution Approach 1:
The system performs self-service by automatically detecting unsafe conditions through the sensor and independently activating the brake without requiring human intervention. The controller autonomously processes sensor data and actuates the brake when speed thresholds are exceeded, making the system self-regulating and enhancing safety while minimizing the need for complex manual oversight.
Solution Approach 2:
The controller serves as an intermediary between the sensor and the brake actuator. It receives signals from the sensor, processes the information according to safety criteria, and translates this into appropriate brake activation commands, mediating between detection and action to simplify the overall control architecture.
3Object-affected harmful factors
If speed sensors and automated brake systems are integrated, then runaway conditions are prevented, but manufacturing complexity and cost increase
Solution Approach 1:
The safety system is segmented into distinct functional modules: a speed sensor for detection, a controller for processing, and a brake actuator for action. This modular segmentation allows each component to be manufactured and tested independently, then assembled into the complete safety system, improving ease of manufacture while maintaining the capability to prevent runaway conditions.
Data Source
AI summary
A manually operated counterweight hoist including a batten operable to support a load, an arbor operable to support one or more counterweights, a hand line operable to move the batten or the arbor, a brake operable to prevent movement of the arbor and the batten by constricting movement of the hand line, a brake actuator operable to activate the brake, a sensor that measures a speed of the arbor, and a controller including an electronic processor. The controller is operatively coupled to the sensor and the brake actuator. The controller is configured to receive a measurement signal from the sensor, determine whether the speed of the arbor exceeds a threshold based on the measurement signal, and activate the brake actuator when the speed of the arbor exceeds the threshold.