Crane Actuator Angle Sensor Integration
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Solution Overview
Problem
Cranes face challenges in accurately detecting the angular position of arms due to the high cost and maintenance of magnetostrictive sensors, and the limited installation space and susceptibility to errors from external angle sensors, especially in designs with compact pivot bearings and fork-shaped receiving areas.
Innovation Solution
A crane design with a rotation angle sensor integrated into the bearing points of the actuator and toggle lever arrangement, allowing for precise angle detection between arms without the need for external sensors, utilizing a stator and rotor configuration within an axial hollow cross-section to optimize space and reduce error susceptibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If magnetostrictive sensors are used for length measurements in hydraulic cylinders, then measurement precision is improved, but device complexity and maintenance costs increase
Solution Approach 1:
The patent extracts the measurement function from the hydraulic cylinder interior to the exterior bearing points. Instead of measuring length inside the cylinder, the system measures the angle of the actuator arm externally and calculates position based on the known relationship between actuator angle and piston position, eliminating the need for complex internal sensors.
Solution Approach 2:
The patent replaces direct mechanical length measurement with angular measurement. By using angle sensors at bearing points to detect the actuator's angular position and correlating this with the known mechanical geometry, the system achieves position measurement without complex magnetostrictive sensors.
2Area of stationary object
If angle sensors are arranged externally on the pivot bearing, then installation space requirements are reduced, but reliability deteriorates due to susceptibility to collisions and errors
Solution Approach 1:
The patent nests the angle sensor within the bearing point structure itself. The sensor is integrated into the bearing assembly where it is mechanically protected by the bearing housing and surrounding structural components, shielding it from external collisions while maintaining measurement capability.
3Measurement precision
If angle sensors are arranged in the pivot bearing area, then measurement precision is improved, but device complexity increases due to limited installation space
Solution Approach 1:
The patent makes the bearing point serve multiple functions: it acts as both the mechanical pivot for the actuator arm and the mounting location for the angle sensor. This multi-functional design eliminates the need for separate sensor mounting structures and reduces overall system complexity.
Solution Approach 2:
The patent merges the angle sensor mounting function with the existing bearing point structure. Instead of adding separate external mounting brackets or structures, the sensor is directly integrated into the bearing assembly, combining measurement and mechanical support functions in one location.
4Productivity
If the crane arm system uses compact fork-shaped receiving areas, then productivity is improved through optimized design, but ease of manufacture deteriorates due to limited sensor installation space
Solution Approach 1:
The patent extracts the sensor installation location from the compact fork-shaped receiving area to the bearing points along the actuator linkage. This allows the fork area to remain compact for productivity while the sensors are positioned elsewhere for ease of installation and maintenance.
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
Crane (1), in particular a forestry crane or loading crane, with a multi-arm arm system, wherein the arm system comprises at least: - a main arm (3), which is preferably pivotably mounted on a crane column (2) - a knuckle arm (4), which is pivotably connected to the main arm (3) via a pivot bearing (5) - at least one actuator (10) for driving a pivoting movement of the knuckle arm (4) relative to the main arm (3), wherein the actuator (10) is pivotably mounted on the main arm (3) at a first end (11) with a bearing point (51) and the actuator (10) is pivotably mounted on the knuckle arm (4) at a second end (12) with a bearing point (52), or is pivotably connected with a bearing point (53) to a toggle lever assembly (19) with at least two levers (20, 30), wherein the toggle lever assembly (19) is pivotally connected with a bearing point (54) is mounted on the main arm (3) and pivotably mounted with a bearing point (55) on the knuckle arm (4),wherein preferably the at least two levers (20, 30) are pivotably connected to each other by a bearing point (53, 56), wherein at least one of the bearing points (51, 52, 53, 54, 55, 56) has a rotation angle sensor (13).