Crane Control System for Exceptional Event Safety
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Solution Overview
Problem
Cranes are at risk during exceptional events such as unusual winds or equipment failures, which can lead to undetected damage and unsafe reactivation, as existing methods fail to adequately secure the crane or ensure compliance with manufacturer instructions.
Innovation Solution
A securing method that uses a control-command system connected to sensors and actuators to detect exceptional events, assess their severity, and implement safety instructions, including movement limitations and alert messages, ensuring the crane operates in a safe mode until conditions are met for safe reactivation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the crane operator ignores alert messages and continues to operate the crane, then productivity is maintained, but the reliability and safety of the crane deteriorates
Solution Approach 1:
The control system dynamically adjusts the crane's operational state based on detected exceptional events. When an exceptional event is detected, the system automatically transitions the crane from nominal operating mode to safe operating mode, dynamically modifying operational parameters to ensure safety while maintaining controlled productivity.
Solution Approach 2:
The system implements a feedback mechanism where sensors continuously monitor crane parameters, the control system compares these against predefined exceptional event criteria, and automatically responds by switching operating modes. This closed-loop feedback ensures that safety conditions are continuously enforced regardless of operator input.
2Reliability
If the crane is secured in safe operating mode after detecting an exceptional event, then the reliability and safety are improved, but the productivity decreases due to movement limitations
Solution Approach 1:
The system provides dynamic operational adaptation by switching between nominal and safe operating modes based on real-time conditions. In safe operating mode, the crane maintains limited operational capability rather than complete shutdown, dynamically adjusting the degree of movement restriction based on the severity and type of exceptional event detected.
3Reliability
If the control system automatically switches to safe operating mode upon detecting an exceptional event, then the reliability is improved, but the ease of operation deteriorates due to automatic blocking of movements
Solution Approach 1:
The control system implements automatic feedback-based mode switching that monitors crane parameters and autonomously transitions between operating modes when exceptional events are detected. This removes the need for operator judgment in safety-critical decisions, ensuring consistent and reliable safety enforcement while the operator retains control in nominal mode.
4Reliability
If multiple sensors and a control system are integrated to detect and respond to exceptional events, then the reliability and safety are improved, but the device complexity increases
Solution Approach 1:
The control system is designed with multi-functionality, serving both normal crane operation control and exceptional event detection and response. The same control unit that manages routine crane operations also monitors sensor data, detects exceptional events, and executes safe operating mode transitions, eliminating the need for separate dedicated safety systems.
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to a crane (1) and a method of securing against the occurrence of an exceptional event, the crane comprising a control system (20) connected to actuators (40, 41, 42) to manage movements of the crane and of a suspended load (5) and integrated within a processing unit (2) of the crane connected to movement, load and safety sensors (3) placed on elements (10, 11) of the crane.The process includes the following steps: - establishing (S1) a list of exceptional events detectable by means of said sensors; - associating (S2) each exceptional event in the list with several severity levels based on a value of the event information; - associating (S3) each exceptional event and for each severity level with a safety instruction relating to the actuators (40, 41, 42) and defining at least one degree of limitation of at least one movement of the crane (1); - the crane (1) operating in a nominal operating mode, - evaluation (S5) of the severity level of the exceptional event; - switching (S6) to a safe operating mode in which the control system (20) applies the safety instruction associated with the evaluated severity level; - issuing (S7) an alert message.