Crane 3D Forbidden Volume Control for Obstacle Proximity
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Solution Overview
Problem
Traditional Working Range Limiters (WRL) systems are inadequate for complex geometries, often preventing cranes from lifting loads near obstacles while trying to avoid collisions, as they treat entire structures as forbidden zones, limiting crane functionality and efficiency.
Innovation Solution
A method and system using a computing device to define a coordinate system, obstacle data, and crane component data, calculating a minimum distance between the crane component and forbidden volumes, allowing controlled movements to avoid collisions while enabling the crane to operate closer to traditionally forbidden zones by limiting movements based on calculated proximity vectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a building is marked as a forbidden zone to prevent a boom from impacting the building, then safety is improved, but the crane cannot lift a load to the top of the building
Solution Approach 1:
The patent divides the 2D forbidden zone into a 3D forbidden volume by introducing a vertical height parameter. This segmentation allows the system to distinguish between horizontal proximity (which should be restricted) and vertical approach (which should be permitted), thereby resolving the contradiction between safety and crane functionality.
Solution Approach 2:
The patent transitions from a two-dimensional forbidden zone (on the ground plane) to a three-dimensional forbidden volume (extending vertically). This dimensional change enables the crane to operate above the forbidden zone without violating safety constraints, as the 3D volume accounts for both horizontal and vertical positions of the boom and hook block.
2Adaptability or versatility
If a building is not designated as being in the forbidden zone, then crane functionality is improved, but the crane could accidentally move into the proximity of the building
Solution Approach 1:
The patent implements real-time monitoring of the hook block's position relative to the forbidden volume boundaries. The system continuously calculates the distance between the hook block and the forbidden volume, and provides feedback to the operator through visual indicators (such as changing colors or patterns on a display) when approaching prohibited zones, thereby maintaining safety while allowing operational flexibility.
3Device complexity
If a traditional WRL system is used, then safety monitoring is simplified, but the system fails when geometry becomes complicated
Solution Approach 1:
The patent replaces traditional mechanical/visual monitoring methods with an electronic control system that uses 3D coordinate geometry calculations. The system automatically computes the spatial relationship between the hook block and forbidden volume boundaries using mathematical models, enabling it to handle complex geometries that would be difficult to manage with manual or mechanical spotting methods.
Data Source
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AI summary
A method for controlling a crane component of a tower crane (90) in proximity of obstacles (400) at a worksite by defining a forbidden volume is disclosed. In the method a distance from the crane component to an outer surface of the forbidden volume is determined and a computing device (300) limits movement of the crane component based on the distance from the crane component to the outer surface of the forbidden volume to avoid entering the forbidden volume with the crane component while the crane is in operation. The crane component is one or more of a boom (110) and a hook block (150).