Crane Spreader Dynamic Envelope Collision Avoidance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Crane operators face challenges in efficiently and safely loading and unloading shipping containers due to limited visibility, leading to inefficient operations and frequent damage or maintenance issues, as they rely on visual memory or manual speed control, resulting in over 50% of container handling crane maintenance costs and downtime.
Innovation Solution
A computerized system using a gantry crane with a transceiver, laser scanner, and motor control to dynamically adjust the speed of the spreader and trolley based on real-time positional data and collision avoidance, creating a protective envelope to prevent collisions by imposing speed limits when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the spreader speed is reduced too soon, then the operating cycles becomes over-extended, but if the spreader speed is reduced too late, a hard landing may occur causing damage
Solution Approach 1:
The system performs preliminary action by calculating and imposing speed limits on the spreader before it reaches the container, based on predicted arrival time and distance. This allows the spreader to decelerate gradually rather than suddenly, preventing hard landings while maintaining efficient operating cycles.
Solution Approach 2:
The system uses feedback by continuously monitoring the spreader's position, velocity, and predicted arrival time, then adjusting speed limits dynamically. The control system receives real-time data from sensors and modifies speed commands to optimize both productivity and damage prevention.
2Ease of operation
If manual speed control is used by operators, then flexibility is maintained, but visibility limitations lead to inefficient operations and frequent damage
Solution Approach 1:
The system implements self-service by enabling the spreader to autonomously monitor its own position, calculate arrival time, and self-regulate its speed without continuous operator intervention. This maintains operational flexibility while eliminating the limitations of manual control due to poor visibility.
Solution Approach 2:
The patent replaces the mechanical visual monitoring system with an electronic sensing and calculation system. Instead of relying on operator vision and manual judgment, the system uses sensors, processors, and automated algorithms to monitor position and control speed, significantly improving productivity.
3Productivity
If higher speeds are maintained for efficiency, then productivity increases, but wear and tear on the spreader and crane mechanism increases
Solution Approach 1:
The system applies dynamics by continuously adjusting the spreader's speed based on real-time conditions rather than maintaining a fixed speed. Speed limits are dynamically modified according to position, velocity, and predicted arrival time, allowing high speeds during safe conditions while reducing speed approaching the container to minimize wear and tear.
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
Enhances operational efficiency and safety by reducing wear and tear, noise, and damage claims, while maintaining maximum speeds during loading and unloading, ensuring smooth operations even in low-visibility conditions, and reducing downtime and maintenance costs.
Implementation Method 1
determining the distance from the transceiver to the path along its length based on the angle of transmission of each pulse and the time until a reflection of that pulse, if any, is received
Data Source
AI summary
A system and method for using a gantry crane to efficiently and safely transport loads such as containers and ship hatch covers from one location to another along a known path while avoiding collisions between the loads and obstructing objects which may be situated in the known path. A transceiver emitting laser beams may be used to establish both the position of the spreader and its load and the profile of the known path. Continuous comparisons are made by computer between the location of a dynamic digital protective envelope constructed around the crane spreader and its load, if any, and a digital representation of the profile of the known path to be traveled by the spreader and its load, if any. In the event, the comparison indicates intersection of the protective envelope and the path profile, a speed limit is imposed on the motor controlling the movement in the X axis of the trolley or in the Z axis of the spreader, as required to prevent a collision.