Integrated Crane Diagnostic System for On-Site Fault Rectification
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Solution Overview
Problem
Construction machines, particularly cranes, require frequent visits to workshops for diagnosis and fault reading, parameterization, and initialization, which reduces their availability due to the lack of internal diagnostic capabilities.
Innovation Solution
Integration of a service and diagnostic device within the construction machine that allows for on-site error identification, correction, and communication with central service points, enabling remote troubleshooting and reducing the need for workshop visits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external diagnostic devices are used in workshops, then diagnosis and fault reading can be performed, but the construction machine must be transported to the workshop, reducing availability
Solution Approach 1:
The construction machine is equipped with an integrated service device that enables self-diagnosis and self-service operations. The control unit can independently execute diagnostic routines, read fault messages, and perform basic service functions without requiring external diagnostic equipment or transportation to a workshop, thereby improving availability while maintaining ease of operation.
2Loss of time
If external diagnostic devices are used, then comprehensive service activities can be performed, but transportation to service centers is required, increasing downtime
Solution Approach 1:
The service device is merged with the construction machine's existing control unit, combining diagnostic, fault reading, and basic service functions into the machine's native control system. This integration eliminates the need for separate external devices and transportation to service centers, reducing downtime while managing system complexity through unified architecture.
Solution Approach 2:
The control unit is designed with multi-functionality, serving both as the primary control system for machine operations and as an integrated service device for diagnosis and fault reading. This universal design eliminates the need for separate dedicated diagnostic equipment, reducing overall system complexity while enabling comprehensive service functions.
3Productivity
If service activities are performed at workshops, then proper diagnostic equipment is available, but frequent transportation reduces productivity
Solution Approach 1:
The construction machine performs service activities autonomously through its integrated control unit, which can execute diagnostic routines, read fault messages, and perform basic service functions on-site. This self-service capability eliminates transportation time to workshops and enables immediate service operations, thereby improving productivity while minimizing service time loss.
Data Source
AI summary
The crane has a service-and/or diagnosis device for carrying out service and/or diagnosis operations and/or for delivering fault messages about the crane. The service-and/or diagnosis device is designed such that initialization and/or parameterization of new modules or components or exchange modules or exchange components of the crane. The service-and/or diagnosis device is also designed to measure and display current and/or voltages and/or signals. The service-and/or diagnosis device has an interface, via which data can be transmitted from or to the diagnosis device in a wireless manner.