Crane Remote Control Module with Modbus RTU Buffering

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Solution Overview

Problem

Current remote control and maintenance systems for cranes are inefficient due to the limitations of existing communications protocols, such as Modbus ASCII and Modbus RTU, which lead to slow communication and intolerance of data packet interruptions, making them unsuitable for remote maintenance via radio or modem.

Innovation Solution

A multifunction device that uses a control module connected to electronic power units via a communications port, capable of detecting and controlling crane functions, and a communications module for data packet transmission via radio using the Modbus RTU protocol, with data packets stored in a memory unit for a longer period to ensure complete reception and transmission, and integrated with GSM/GPRS and RS 232/485 ports for reliable operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If Modbus ASCII protocol is used for remote communication, then communication compatibility is improved, but communication speed deteriorates significantly

Engineering Contradiction:

Improvecommunication compatibilityVSAvoidcommunication speed

Core Design Contradiction:

Adaptability or versatilityVSSpeed

Solution Approach 1:

The patent changes the data representation parameter from ASCII encoding to binary encoding. The communications module converts crane operation data into binary format for transmission, which reduces the number of bytes required and increases communication speed while maintaining protocol compatibility through adaptive data formatting.

Inventive Principle:

Principle #35Parameter changes

2Speed

If Modbus RTU protocol is used for remote communication, then communication speed is improved, but tolerance to data packet interruptions deteriorates

Engineering Contradiction:

Improvecommunication speedVSAvoidtolerance to data packet interruptions

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The control module performs preliminary actions by implementing a buffering system that temporarily stores incoming data packets before processing. This buffering mechanism allows the system to handle interruptions gracefully by preserving data integrity and enabling retransmission without losing critical information, thus improving reliability while maintaining high-speed binary communication.

Inventive Principle:

Principle #10Preliminary action

3Measurement precision

If direct operator intervention is used for crane maintenance, then problem solving accuracy is improved, but travel expenses and labor costs increase

Engineering Contradiction:

Improveproblem solving accuracyVSAvoidtravel expenses and labor costs

Core Design Contradiction:

Measurement precisionVSQuantity of substance

Solution Approach 1:

The patent implements self-service functionality through the remote maintenance system. The control module automatically monitors crane operation parameters, detects anomalies, and transmits diagnostic data to remote operators. This enables the crane system to identify and report problems autonomously, allowing remote experts to provide accurate diagnostics without physical presence, thereby eliminating travel costs while maintaining high problem-solving accuracy through comprehensive data analysis.

Inventive Principle:

Principle #25Self-service

4Measurement precision

If direct operator intervention is used for crane maintenance, then diagnostic accuracy is improved, but intervention time increases

Engineering Contradiction:

Improvediagnostic accuracyVSAvoidintervention time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces the mechanical system of physical operator intervention with an electronic communication system. The control module continuously collects and transmits operational data electronically to remote operators, who can perform diagnostics instantly without traveling to the crane site. This substitution of physical presence with electronic data transmission maintains diagnostic accuracy while dramatically reducing intervention time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP2168903B1A multifunction device for remote maintenance and remote control, in particular for cranes

Publication Date: 2012.02.08 GRU BENEDINI DI BENEDINI GIULIO E FAMIGLIA

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AI summary

A multifunction device for remote maintenance and remote control applications for cranes, in which a crane is provided with a plurality of motors (5, 8) for driving mobile parts of the crane, each of the plurality of motors (5, 8) being commanded by a respective electronic control unit (6, 9). The multifunction device comprises at least a control module (14) connected, via at least a communications port (15, 16, 19), to the electronic control units (6, 9), the at least a control module (14) gathering data associated to controlling functions of the crane, and further comprising at least a communications module (20) associated to the control module (14), which communications module (20) transmits and receives via radio data packets of information relating to functioning of the crane.