Crane Rope Falls Determination Using Sensor Fusion

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Solution Overview

Problem

Conventional crane devices with overload prevention systems face increased manufacturing costs due to the need for dedicated limit switches to determine the actual number of rope falls, which can lead to potential rope damage or over-winding issues if the set and actual number of falls are mismatched.

Innovation Solution

A crane device equipped with a feed length detection unit, boom angle detection unit, and a number-of-falls determination unit that calculates the suitability of the number of falls based on the feed length, hoist angle, and boom length, allowing for multiple types of rope falls settings without increasing the number of parts, thereby determining if the actual and set number of falls are the same.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If dedicated limit switches are provided to determine the actual number of rope falls, then measurement precision is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvedetermination accuracy of actual number of fallsVSAvoidnumber of parts

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent makes existing components (winch, boom angle sensor, feed length sensor) perform the additional function of determining the actual number of rope falls. The controller integrates multiple detection functions into a unified calculation system, eliminating the need for dedicated limit switches while maintaining determination accuracy.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system uses its own existing sensors and operational parameters (feed length from winch, boom angle, boom length) to self-determine the actual number of rope falls. The crane device leverages its inherent measurement capabilities rather than requiring external dedicated detection devices.

Inventive Principle:

Principle #25Self-service

2Reliability

If the number of falls set in the overload prevention device is larger than the actual number of falls, then rope damage occurs because the crane operation is not restricted properly, but increasing the number of falls setting does not directly cause the problem

Engineering Contradiction:

Improveoverload prevention accuracyVSAvoidrope damage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The system continuously monitors the actual number of rope falls by calculating from feed length, boom angle, and boom length, then feeds this information back to the overload prevention device. This feedback mechanism ensures the overload prevention settings always match the actual rope configuration, preventing both rope damage and over-winding incidents.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system determines the actual number of rope falls before crane operations commence or when configuration changes occur. By establishing the correct number of falls in advance, the overload prevention device can be properly configured to prevent rope damage before it occurs.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If the number of falls set in the overload prevention device is smaller than the actual number of falls, then over-winding state occurs during hook block raising and reverse winding occurs during lowering, but the setting itself is not the direct cause

Engineering Contradiction:

Improvecrane operation efficiencyVSAvoidover-winding and reverse winding

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The continuous feedback mechanism calculates the actual number of rope falls based on real-time feed length, boom angle, and boom length measurements. This ensures the overload prevention device maintains the correct number of falls setting during operations, preventing over-winding during hook block raising and reverse winding during lowering.

Inventive Principle:

Principle #23Feedback

4Adaptability or versatility

If multiple types of number of rope falls are settable, then adaptability is improved, but the complexity of determining the actual number of falls increases

Engineering Contradiction:

Improvenumber of falls configuration flexibilityVSAvoiddetermination system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The unified determination system using existing sensors (feed length sensor, boom angle sensor) and controller calculations serves multiple purposes: it determines the actual number of rope falls for any configured number of falls type, supports overload prevention, and prevents over-winding. This universal approach handles multiple configurations without increasing system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12180043B2Crane device, method for determining number of falls, and computer readable non-transitory recording medium

Publication Date: 2024.12.31 TADANO LTD

AI summary

A crane device is capable of setting multiple types of number of rope falls between a tip of a boom and a hook block, and includes: a feed length detection unit that detects a feed length of a rope fed from a winch on which the rope is wound; a boom angle detection unit that detects a boom hoist angle; and a number-of-falls determination unit that calculates information for determining the suitability of the number of falls for the rope on the basis of the feed length, hoist angle, boom length of the boom in a state of hoisting a grounded load.