Counterweight Sensing System for Lifting Machines
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Solution Overview
Problem
Existing lifting machines, such as cranes, lack an efficient and reliable method for automatically determining the amount of counterweight present, relying on operator input which can lead to errors and inefficiencies.
Innovation Solution
A counterweight sensing system utilizing hydraulic cylinders with pressure and position sensors, a controller to determine the counterweight amount, and an operator verification process to ensure accuracy, along with a locking mechanism to secure the counterweight in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If automatic sensing system is implemented, then measurement precision and reliability are improved, but device complexity increases
Solution Approach 1:
The patent replaces manual operator input with an automatic sensing system that uses pressure sensors and position sensors to detect counterweight amount. The controller processes sensor signals to automatically determine counterweight, eliminating the need for operator estimation and manual input, thereby improving measurement precision while accepting increased system complexity.
Solution Approach 2:
The sensing system enables the crane to automatically detect and determine its own counterweight configuration without external intervention. The controller receives signals from pressure and position sensors, processes this information, and automatically determines the counterweight amount, allowing the system to self-verify its operational parameters.
2Reliability
If multiple sensors are used for verification, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent implements a feedback verification system where the controller receives signals from both pressure sensors and position sensors, cross-checks this information against expected values, and provides feedback to the operator through the display. This multi-sensor feedback mechanism enhances reliability by verifying counterweight detection through multiple independent measurement channels.
Solution Approach 2:
The system performs preliminary verification of counterweight detection before allowing crane operation. The controller checks sensor readings and compares them against expected counterweight configurations, and only permits operation when verification is successful, preventing operation with incorrect or unverified counterweight settings.
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 enables accurate and automatic detection of counterweight, reducing operator errors and ensuring reliable crane operation by providing a precise and efficient method for counterweight determination and verification.
Implementation Method 1
A pressure sensor is provided for sensing an amount of pressure on a rod end of the hydraulic cylinder of the lifter
Implementation Method 2
A first hydraulic cylinder includes a rod adapted for being releasably connected to the platform and for moving the platform from a lowered position to a raised position
Implementation Method 3
A first position sensor is provided for sensing a position of the rod of the hydraulic cylinder
Data Source
AI summary
A lifting machine with a counterweight includes a sensing system for assisting in ensuring proper operating conditions are reliably achieved. The machine includes a lifter for moving the counterweight from a lowered position to a raised position. A first sensor is associated with the lifter for sensing a parameter corresponding to an amount of the counterweight (such as a pressure value associated with the rod end of a lifting cylinder), and a second sensor is provided for sensing a condition of the lifter (such as the position or extended length of the lifting cylinder). The amount of counterweight present may be determined by the output of the first sensor when the lifter is in a pre-determined (e.g., midpoint) position. The operator may be polled to verify the amount of counterweight present, thus providing a check against unintended operating conditions and ensure that reliable operation of the lifting machine is achieved.