Crane Moment Load Control Using Tri-Axis Inclinometer
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Solution Overview
Problem
Existing crane control systems fail to effectively monitor and restrict operations based on crane moment load, leading to potential rollovers due to excessive moment loads caused by loads being lifted at a distance beyond the crane's safe operating radius, and do not adequately consider factors like chassis incline and boom rotation.
Innovation Solution
A crane control system that monitors boom raising cylinder pressure, boom angle, chassis incline, outrigger location, and hydraulic pressure using a tri-axis inclinometer to calculate the crane's moment load, with three operational ranges to restrict crane movements within its safe capacity, including warnings and hydraulic control adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the crane operates with extended boom reach to lift loads at a distance, then the working radius and lifting capability are improved, but the moment load increases beyond safe operating limits causing potential rollover
Solution Approach 1:
The control system performs preliminary calculations of the moment load before allowing crane operation. The processor calculates the moment load based on load weight, boom length, boom angle, and chassis incline, and restricts hydraulic actuator operation if the calculated moment load exceeds the predetermined safe limit, preventing unsafe operations before they occur
Solution Approach 2:
The system continuously monitors operational parameters including load weight, boom position, and chassis incline, and uses this feedback to dynamically calculate the moment load and adjust the safe operating limit accordingly. The control system receives feedback from sensors and adjusts hydraulic actuator operation based on real-time moment load calculations
2Productivity
If the crane operator has full control over hydraulic actuators for rapid boom extension and positioning, then the operation speed and productivity are improved, but the risk of exceeding safe moment load is increased
Solution Approach 1:
The control system acts as an intermediary between the operator's commands and the hydraulic actuators. The processor intercepts control signals, calculates the resulting moment load, and only allows actuator operation if the moment load remains within the safe operating limit, thus mediating between operator intent and safety constraints
Solution Approach 2:
The control system applies preliminary anti-action by restricting hydraulic actuator operation before the crane can enter an unsafe state. The processor prevents boom extension or positioning movements that would cause the moment load to exceed the safe limit, countering potential harmful actions before they occur
3Adaptability or versatility
If the crane operates on inclined surfaces to access difficult terrain, then the adaptability and versatility are improved, but the safe working radius is reduced due to increased moment load
Solution Approach 1:
The system dynamically changes the safe operating limit parameter based on chassis incline angle. The processor calculates the moment load considering the incline angle, and adjusts the maximum allowable moment load accordingly, allowing the crane to operate safely on inclined surfaces with modified operational parameters
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 ensures safe crane operation by preventing excessive moment loads, reducing the risk of rollovers and damage, and maintaining stability by restricting crane movements when approaching or exceeding safe operating limits, thus enhancing operator safety and equipment integrity.
Implementation Method 1
A further feature of one embodiment of the present invention is the use of a tri-axis inclinometer having a master two-axis inclinometer in connection with a slave single-axis inclinometer. The two-axis inclinometer is mounted to the base of the crane or the chassis. It senses the incline of the chassis in two perpendicular directions. The slave inclinometer is attached to the boom and senses the boom angle.
Data Source
AI summary
The present invention is a crane operating system and method which monitors the crane moment load in order to keep the crane within the safe operating envelope. In determining the current crane moment load the system considers boom raising cylinder pressure, boom angle, chassis incline, as well as hydraulic pressure.