Crane Control System Automatic De-rate for Side-Load Stability
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Solution Overview
Problem
Existing truck-mounted crane operating systems fail to prevent instability and rollover accidents caused by lifting heavy loads alongside the truck, as they rely on weight or hydraulic pressure monitoring, which does not account for the load's position relative to the truck's center of gravity.
Innovation Solution
A crane control system that automatically de-rates the maximum lifting capacity based on the boom's location using inductive proximity sensors and stationary steel targets to define zones around the truck, reducing the lift capacity by a predetermined percentage when the boom is in specific side zones without operator input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If weight or hydraulic pressure monitoring is used to monitor load, then the crane can detect load weight, but it cannot prevent instability and rollover accidents caused by lifting loads alongside the truck
Solution Approach 1:
The patent transitions from monitoring only the weight dimension to monitoring the spatial position dimension of the load. By using sensors to detect the boom's angular position and calculating the load's horizontal distance from the truck's centerline, the system adds a spatial dimension to the monitoring approach, enabling prevention of rollover accidents caused by side-loading regardless of the load's weight.
2Adaptability or versatility
If the crane operates at full capacity regardless of boom position, then the crane is versatile and can lift any load, but it becomes unstable when lifting loads alongside the truck
Solution Approach 1:
The patent implements dynamic capacity adjustment based on real-time boom position detection. The crane's lifting capacity is not fixed but dynamically modifies itself according to the boom's angular position and the resulting load moment arm. When the boom is in safe zones, full capacity is allowed; when approaching dangerous zones, the capacity is reduced, creating a dynamic balance between versatility and stability.
Solution Approach 2:
The system changes the operational parameters of the crane based on boom position. Specifically, the allowable load weight parameter is modified according to the horizontal distance of the load from the truck's centerline. This parameter change ensures that the crane operates safely across different positions while maintaining versatility when conditions permit.
3Ease of operation
If the crane allows lifting in all positions, then the operator has full freedom of operation, but the risk of rollover accidents increases significantly
Solution Approach 1:
The patent implements a feedback control system where sensors continuously monitor boom position, the controller calculates the load moment arm and compares it against safety thresholds, and the system provides real-time feedback to the operator through warnings or automatic capacity reduction. This feedback mechanism maintains operator freedom within safe operating boundaries while actively preventing rollover accidents.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Prevents dangerous lifts alongside the truck, significantly reducing the likelihood of rollover accidents by automatically adjusting the crane's capacity based on the boom's position, ensuring safer operations without additional operator intervention.
Implementation Method 1
The control system uses an inductive proximity sensor located on the base of the crane to locate stationary steel targets located around the base of the crane
Data Source
AI summary
A crane control system and method which automatically de-rates the maximum capacity of the crane when the boom is located in a first zone located on one side of the truck or in a second zone located on the opposite side of the truck. The control system de-rates the crane without input from the crane operator. The control system may use an inductive proximity sensor located on the base of the boom to locate stationary steel targets located around the base of the boom. The targets approximate the outer ranges of the first and second zones.