Crane Rope Control via Segmented Drive and Storage Reel
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Solution Overview
Problem
Existing crane systems face issues with rope management at extreme lifting heights, requiring large structures, high torque, and shortening the operating life of the rope due to excessive rope length and angle, as well as difficulties in adjusting rope tightness.
Innovation Solution
The method involves controlling one machinery with a speed instruction and the other with a torque instruction, using an electric motor and gearless solutions, where the driving wheel is driven by one machinery and the storage reel by another, with adjustments in torque and speed to maintain constant rope force and prevent rope wandering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the rope is coiled onto a drum in one layer, then the drum length becomes large requiring large space and strong structures, but the rope angle becomes large shortening operating life
Solution Approach 1:
The rope coiling system is segmented into two separate components: a driving drum for active rope payout and a storage reel for passive rope storage. This segmentation allows the driving drum to remain compact while the storage reel handles the multi-layer coiling, resolving the contradiction between drum length and rope operating life.
Solution Approach 2:
The storage reel acts as an intermediary component between the driving drum and the rope. It receives the rope from the driving drum and coils it into multiple layers, mediating the rope management function to reduce the driving drum length while maintaining proper rope angle and reducing wear.
2Ease of operation
If a storage reel is used to coil extra rope into multiple layers, then rope management is improved, but large torque is required in the driving wheel machinery
Solution Approach 1:
The power transmission system is segmented into two independent machinery systems: one driving the friction-operated driving wheel and another driving the storage reel. This segmentation distributes the torque requirements, allowing the driving wheel machinery to operate at lower torque while the storage reel machinery handles the coiling torque independently.
Solution Approach 2:
The system changes the control parameter for the storage reel from speed control to torque control. By supplying torque instructions rather than speed instructions to the storage reel machinery, the system optimizes power distribution and reduces the torque burden on the driving wheel machinery while improving rope management.
3Force
If spiral spring is used for tightening the rope on the storage reel, then sufficient friction is accomplished, but difficulties arise if the lifting height is large
Solution Approach 1:
The mechanical spiral spring tightening system is replaced with a controlled torque application system. The storage reel machinery receives torque instructions from the control system, replacing the passive mechanical spring mechanism with an actively controlled system that can adapt to any lifting height.
Solution Approach 2:
The tightening force mechanism changes from a mechanical spring system to a controlled torque system. By changing the control parameter to torque instructions for the storage reel machinery, the system gains adaptability to different lifting heights while maintaining sufficient friction force for proper rope tightening.
4Area of stationary object
If direct coiling onto the drum into multiple layers is used, then compact structure is achieved, but large torque and high rope tension force are required shortening operating life
Solution Approach 1:
The coiling function is segmented from the driving drum to a separate storage reel. The driving drum maintains a compact size for multi-layer coiling, while the storage reel independently manages the rope tension and coiling torque, resolving the contradiction between compact structure and rope operating life.
Solution Approach 2:
The storage reel serves as an intermediary that decouples the compact multi-layer coiling function from the driving drum. It receives rope from the compact driving drum and manages the coiling process with controlled torque, maintaining compact structure while reducing rope tension and extending operating life.
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
This approach results in a compact, strength-efficient structure with improved rope operating life by reducing torque and tension force, preventing rope wandering, and maintaining constant rope force, thus extending the lifespan of the rope.
Implementation Method 1
controlling a rope part connected to a hook of the crane with a friction-operated driving wheel
Data Source
Figure 1~2B
Figure 3~4
AI summary
The invention relates to a method for controlling a crane, the method comprising controlling a rope part (13) connected to a hook of the crane with a friction- operated driving wheel (3), extra rope (12) being coiled into a plurality of layers onto a storage reel (4). In the method, two machineries (1, 2) are used, of which the first (1 ) is intended for the driving wheel (3) and the other (2) for the storage reel (4), one machinery (1, 2) being controlled with a speed instruction and the other machinery (1, 2) with a torque instruction.