Crane Control System Using Imaging Sensors for Safety Zone Detection
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Solution Overview
Problem
Gantry cranes face hazards during load transport due to potential snagging and uncontrolled movements, particularly when lifting heavy loads like machine dies, which can result in accidents and require careful operation to avoid collisions and ensure safety.
Innovation Solution
A crane control system equipped with a hoist, imaging sensors for detecting personnel in safety regions, and load sensors to inhibit crane operation when safety conditions are compromised, such as detecting a person in the safety zone or excessive load, thereby preventing uncontrolled movements and collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the crane operates at normal speed to maintain productivity, then productivity is improved, but safety is worsened due to potential snagging and uncontrolled movements
Solution Approach 1:
The system performs preliminary actions by detecting persons in safety zones before hazardous movements occur. The imaging sensor continuously monitors for personnel in defined safety regions, and the controller prepares to inhibit operation in advance, preventing accidents before they can happen while maintaining normal operation speeds.
Solution Approach 2:
The system implements feedback by using imaging sensors to detect persons in safety zones and providing real-time information to the controller. The controller responds by inhibiting crane operation when persons are detected, creating a closed-loop safety system that continuously monitors and adjusts operation based on detected conditions.
2Ease of operation
If the crane operates with manual control to maintain ease of operation, then ease of operation is improved, but safety is worsened due to human error and lack of automated monitoring
Solution Approach 1:
The imaging sensor acts as an intermediary between the operator and the crane system, providing automated monitoring of safety zones. The sensor detects persons and communicates this information to the controller, which then inhibits operation automatically, serving as a mediator that enhances safety without removing manual control capabilities.
Solution Approach 2:
The system replaces manual safety monitoring with automated imaging sensors and electronic control. Instead of relying on human operators to visually monitor safety zones and react appropriately, the system uses optical sensors and automated control logic to detect persons and inhibit operation, reducing human error while maintaining ease of operation.
3Productivity
If the crane allows operation in all conditions to maintain productivity, then productivity is improved, but harmful factors increase due to potential collisions and uncontrolled movements
Solution Approach 1:
The system applies preliminary anti-action by detecting persons in safety zones in advance and inhibiting crane operation before hazardous movements can occur. This preventive approach counteracts potential harmful effects such as collisions and uncontrolled movements by stopping the crane before the dangerous situation develops.
Solution Approach 2:
The imaging sensor provides continuous feedback on the presence of persons in safety zones, enabling the controller to make real-time decisions about operation. This feedback mechanism allows the system to maintain productivity when safe and prevent harmful effects when persons are present, dynamically adjusting operation based on detected conditions.
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
The system enhances crane safety by preventing operation when personnel are in danger zones or excessive loads are detected, reducing the risk of accidents and ensuring controlled movements, thus promoting safer crane operation.
Implementation Method 1
an imaging sensor for detecting a person in a defined safety region
Data Source
AI summary
The present invention relates to a crane (101). The crane (101) has a hoist (113), movable in at least one lateral direction (X, Y), for performing a lifting operation. A controller (125) is provided for controlling lateral movement of the hoist (113). An imaging sensor (127) is provided for detecting a person in a defined safety region (145, 147). The controller (125) is configured to inhibit operation of the crane (101) when the imaging sensor (127) detects a person in said safety region (145, 147). The invention also relates to a control system for a crane (101) and a related method.