Dock Leveller Control Using Motor Power for Adaptive Raise Timing
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Solution Overview
Problem
Existing dock levellers operate inefficiently due to fixed raise times and lack of adaptive control, leading to energy wastage and inability to detect motor defects, despite the use of costly and bulky motor protection circuits.
Innovation Solution
A controller that monitors motor power consumption to determine the maximally raised position, calculates speed ratios, and adjusts operation times based on these measurements, allowing for efficient operation and detecting potential motor issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If fixed raise time is used for dock leveller operation, then the dock leveller can reach its maximally raised position, but energy is wasted due to operation beyond necessary time
Solution Approach 1:
The controller monitors motor current consumption in real-time and uses this feedback to detect when the dock leveller reaches its maximally raised position. The system adjusts the operation time dynamically based on actual operational needs rather than using a fixed predetermined time, thereby eliminating energy wastage from excessive operation.
Solution Approach 2:
The patent implements dynamic adjustment of the dock leveller's operation time based on real-time monitoring of motor current consumption. The system transitions from a static fixed-time operation mode to a dynamic adaptive mode where the operation duration is continuously optimized based on actual positional feedback derived from power consumption patterns.
2Productivity
If manual adjustment of operation time is performed by skilled users, then some optimization can be achieved, but it cannot guarantee most efficient operation due to human limitation
Solution Approach 1:
The controller automatically determines the optimal operation time by monitoring motor current consumption patterns without requiring manual intervention. The system performs self-adjustment based on real-time electrical parameters, eliminating the need for skilled users to manually tune operation times while guaranteeing optimal efficiency through objective electrical measurements.
Solution Approach 2:
The patent replaces manual mechanical adjustment methods with an automated electrical monitoring system. Instead of relying on human operators to physically adjust or estimate operation times, the system uses electrical current measurements to automatically determine and optimize operational parameters, achieving higher precision and reliability.
3Reliability
If physical motor protection circuits are installed, then motor protection is provided, but the circuits are costly and bulky
Solution Approach 1:
The controller performs multiple functions using the same electrical monitoring capability: it detects the maximally raised position through current consumption patterns, monitors motor protection parameters, and optimizes operation timing. This multi-functional approach eliminates the need for separate dedicated protection circuits, reducing system complexity and cost while maintaining comprehensive motor protection.
Solution Approach 2:
The patent combines the functions of position detection, motor protection, and operation optimization into a single integrated controller that monitors electrical parameters. By merging these previously separate functions into one unified system based on power consumption analysis, the patent eliminates the need for bulky physical protection circuits while maintaining all necessary protective capabilities.
4Reliability
If physical motor protection circuits are used, then some protection is provided, but certain motor defects cannot be detected
Solution Approach 1:
The patent replaces physical protection circuits with an electrical monitoring system that analyzes motor current consumption patterns. This electrical approach provides more comprehensive defect detection capabilities by identifying subtle changes in power consumption that indicate developing motor issues, offering superior reliability without increased physical complexity.
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 controller ensures dock levellers operate for the minimum necessary time, reducing energy wastage and replaces bulky motor protection circuits with adaptive functionality, enhancing efficiency and reliability.
Implementation Method 1
the controller is configured to determine when the dock leveller is approaching a maximally raised position, by detecting an increase in power consumption of the motor
Data Source
Figure 1A~1C
Figure 2A~2D
Figure 3
AI summary
A control device for a dock leveller system which is able to determine when the dock leveller is at a maximally raised position where its ramp and lip are fully extended by monitoring an increase in power consumption of the dock leveller motor, and automatically adjusts the dock leveller motor running time to optimal based on the dock leveller travel time between various different positions.