Crane Winch Drum Layer Estimation Using Rope Length and Rotation

Solution Overview

Problem

Existing methods for estimating the number of wound layers of a wire rope around a winch drum are inaccurate when the rope is shortened by cutting or an unprescribed length is used.

Innovation Solution

An estimation apparatus comprising a calculation unit, detection unit, and control unit that calculates the delivery length and rotational amount of the winch drum to accurately estimate the number of wound layers based on differences in orientation and rotational amount.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the rope length is used to estimate the number of wound layers, then the estimation can be performed with simple equipment, but the accuracy deteriorates when the rope is shortened by cutting or an unprescribed length is used

Engineering Contradiction:

Improveaccuracy of wound layer estimationVSAvoidcomplexity of estimation system

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical measurement method (direct measurement of rope length) with a sensor-based detection system. A sensor detects the actual number of wound layers by measuring the position or characteristics of the rope on the drum, substituting the mechanical rope length measurement with an electronic sensing mechanism that provides more accurate and reliable data regardless of rope length variations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system incorporates feedback mechanisms where the sensor continuously monitors the wound layer configuration and provides real-time information to the control system. This feedback loop allows the system to adapt to changes in rope length and configuration, maintaining accurate estimation even when the rope is shortened or modified, by continuously adjusting the measurement based on actual sensor readings.

Inventive Principle:

Principle #23Feedback

2Adaptability or versatility

If the rope is shortened by cutting or an unprescribed length is used, then the rope can be adapted to different applications, but the number of wound layers is likely to be estimated incorrectly

Engineering Contradiction:

Improveadaptability of rope lengthVSAvoidaccuracy of wound layer estimation

Core Design Contradiction:

Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

The patent replaces the mechanical measurement method (direct measurement of rope length) with a sensor-based detection system. A sensor detects the actual number of wound layers by measuring the position or characteristics of the rope on the drum, substituting the mechanical rope length measurement with an electronic sensing mechanism that provides more accurate and reliable data regardless of rope length variations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system changes the measurement parameter from rope length to wound layer count directly. Instead of estimating layers based on rope length (which is affected by cutting or modification), the system directly measures the number of wound layers through sensor detection, thereby maintaining accuracy even when the rope length is adapted for different applications.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS12492104B2Estimation apparatus and crane

Publication Date: 2025.12.09 TADANO LTD

AI summary

Provided is an estimation apparatus for estimating a number of wound layers of a wire rope in a crane including a boom, a winch drum, and the wire rope wound around the winch drum, the estimation apparatus being mounted on the crane, the estimation apparatus including: a calculation unit that calculates a delivery length of the wire rope; a detection unit that detects a rotational amount of the winch drum; and a control unit that estimates the number of wound layers, based on a difference in the delivery length of the wire rope and a difference in the rotational amount of the winch drum between a first orientation and a second orientation of the boom.