Crane Climbing Automation Using Sensor-Guided Mast Section Handling
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Solution Overview
Problem
Crane climbing is labor-intensive and poses a significant risk of accidents due to the manual labor involved in inserting or removing mast sections, which is inefficient and hazardous for personnel.
Innovation Solution
A climbing system for cranes equipped with sensors and a control unit that automates the insertion and removal of mast sections by monitoring the state of connecting means, guiding frames, and lifting devices, allowing for automated assembly and disassembly using electrical, pneumatic, and hydraulic devices, and integrating with the crane's control system for coordinated operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual labor is used to insert or remove mast sections, then the climbing operation can be performed with simple equipment, but the labor intensity increases and accident risk increases
Solution Approach 1:
The patent replaces manual mechanical operations with an automated control system that uses sensors to detect the position and state of mast sections, then automatically controls the climbing device to insert or remove mast sections. This substitution of manual mechanical work with an automated electromechanical system reduces labor intensity while managing the complexity through integration of control functions.
Solution Approach 2:
The climbing device is equipped with sensors that automatically detect the state of connecting means and control elements, enabling the system to monitor and adjust its own operation without continuous manual intervention. The control unit processes sensor signals and automatically controls the climbing device, allowing the system to serve itself in terms of monitoring and basic control functions.
2Device complexity
If manual labor is used to insert or remove mast sections, then the equipment requirements are minimized, but the accident risk for personnel increases
Solution Approach 1:
By replacing manual operations with an automated control system that uses sensors and electronic control, the patent eliminates personnel from hazardous manual tasks involving mast section insertion and removal. The automated system provides more consistent and reliable control, reducing the variability and human error factors that contribute to accidents.
Solution Approach 2:
The patent incorporates sensors that continuously monitor the state of connecting means, mast section positions, and control element states. This feedback is processed by the control unit, which automatically adjusts the climbing device operation to maintain safe and correct assembly states, providing real-time monitoring and correction capabilities that enhance reliability.
3Ease of operation
If automated control is implemented with sensors and control units, then the labor intensity is reduced, but the device complexity increases
Solution Approach 1:
The control unit is designed to perform multiple functions: it receives signals from various sensors, processes information about mast section positions and connecting means states, controls the climbing device movements, and manages the automated insertion/removal operations. By consolidating these diverse functions into a single control unit, the patent manages complexity through functional integration rather than requiring separate control systems for each function.
Solution Approach 2:
The patent combines the control functions for the climbing device, sensor signal processing, and automated mast section handling into an integrated control system. The control unit merges multiple control tasks and the sensor network merges multiple detection functions, creating a unified automated system that manages complexity through consolidation rather than proliferation of separate components.
4Productivity
If automated control is implemented, then the need for manual labor is reduced, but the system complexity increases
Solution Approach 1:
The automated system with sensors and control units enables the climbing device to operate with minimal human intervention. The sensors automatically detect mast section positions and connecting means states, the control unit processes this information, and the system automatically executes the insertion or removal operations, making the system self-sufficient in terms of monitoring and control execution.
Solution Approach 2:
The system uses sensors to continuously monitor the state of connecting means and mast sections, providing real-time feedback to the control unit. This feedback loop enables automated adjustment and control of the climbing operation, allowing the system to self-correct and maintain optimal operation without manual intervention, thereby improving productivity through automated closed-loop control.
Data Source
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AI summary
The present invention relates to a climbing system 1 for a crane. The system comprises a climbing device 2 for inserting or removing a mast section 3 from a tower structure 4 of a crane, and a control unit 5 for controlling the climbing device 2. The system is further characterized in that it includes a first sensor 51 for monitoring the state of a connecting element of the climbing device 2 and/or the tower structure 4, wherein the first sensor 51 is connected to the control unit 5. This makes it possible to simplify the climbing process of a crane and to increase the safety of the climbing process.