Crane Control Module Joystick Override Collision Avoidance
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Solution Overview
Problem
Conventional systems for manually operated cranes fail to effectively utilize elevation details of obstacles and intervene with joystick outputs to avoid collisions, leading to decreased productivity, increased costs, and safety risks.
Innovation Solution
A crane control system that includes a control module interfacing with the crane control system to override joystick outputs, using stored site-specific elevation plans and crane configurations to intervene with crane movement, with real-time visualization and position sensing to predict and prevent collisions by slowing or stopping the crane based on predetermined thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional real-time monitoring systems with alarms are used, then obstacle detection capability is provided, but collision avoidance effectiveness deteriorates because operator reaction time is insufficient
Solution Approach 1:
The system performs preliminary actions by automatically calculating crane trajectories, identifying obstacles ahead of time, and preparing avoidance maneuvers before the operator needs to react. The control module pre-computes safe paths and prepares intervention signals, so when a collision risk is detected, the system can immediately execute pre-planned avoidance actions rather than relying on operator reaction time.
Solution Approach 2:
The control module acts as an intermediary between the operator's joystick inputs and the crane's motion execution. It intercepts joystick signals, processes them through collision avoidance algorithms, and modifies the control commands before they reach the crane actuators. This intermediary layer automatically adjusts crane movement to avoid obstacles while preserving operator intent, eliminating the need for direct operator reaction to alarm signals.
2Reliability
If automated crane movement control is implemented, then collision avoidance improves, but operator control capability deteriorates
Solution Approach 1:
The system implements continuous feedback by monitoring crane position, joystick inputs, and obstacle locations in real-time. The control module constantly compares the crane's actual trajectory with safe operating zones and automatically adjusts control signals to maintain collision-free operation. This feedback loop operates transparently to the operator, who retains full control authority while the system provides automatic safety adjustments.
Solution Approach 2:
The system applies partial automation by intervening only when collision risks are detected, rather than fully automating crane control. The control module processes all joystick inputs but only modifies commands when obstacles are present, leaving normal operation entirely under operator control. This partial action approach maintains operator capability while providing automated safety enhancement exactly when needed.
3Measurement precision
If real-time crane position monitoring is implemented, then collision detection capability improves, but system complexity increases
Solution Approach 1:
The control module serves multiple functions: it processes joystick inputs, calculates crane trajectory, identifies obstacles, computes safe paths, and generates control commands. By consolidating these diverse functions into a single multi-functional control unit, the system achieves high measurement precision and collision detection capability without proportionally increasing overall system complexity.
Solution Approach 2:
The system merges position sensing, obstacle detection, trajectory calculation, and control command generation into an integrated control module. Rather than separate systems for each function, the control module combines all these elements into a unified architecture that shares computational resources and data processing pathways, reducing overall system complexity while maintaining high measurement precision.
Data Source
AI summary
A crane control system including a control module configured to interface with a crane control system to intervene with crane movement to avoid a collision with an obstacle, plans stored in memory for use by the control module representing vertical elevation or elevation ranges of a job site and identifying obstacles, a plurality of crane configurations stored in memory, and a display interface displaying a selected plan, crane configuration and real-time crane position. A method for controlling crane movement to avoid a collision with an obstacle.