Fixed-Laser Crane Positioning for Anti-Skew Rail Alignment
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Solution Overview
Problem
Existing laser-based positioning systems for overhead cranes are prone to skewing when mounted on movable portions of the crane, leading to inaccurate distance measurements and potential safety hazards due to misalignment.
Innovation Solution
Mounting the laser beam source on a fixed and non-moving structure within the facility, such as a wall, to generate beams that determine distances to reflectors on the crane, ensuring precise positioning and alignment by using anti-skew control logic to adjust the crane's position if skewing occurs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the laser is mounted on the tram or trolley that moves along crane rails, then the laser can track the crane movement, but the laser beam becomes skewed when rollers are not in sync, leading to inaccurate distance measurements
Solution Approach 1:
Instead of mounting the laser on the moving crane (traditional approach), the patent inverts the arrangement by mounting the laser on a fixed structure and the reflector on the moving crane. This inversion eliminates the skewing problem because the laser remains stationary while the reflector moves with the crane, ensuring the laser beam always points at the reflector without alignment issues.
2Ease of operation
If manual control is used with a person following the crane, then the crane can be controlled in real-time, but the person may fall off catwalks or lose attention causing life-threatening movements
Solution Approach 1:
The system uses automatic laser-based positioning with reflectors mounted on the crane to enable self-positioning and self-control. The crane automatically receives positioning data from the laser system and can autonomously navigate to desired locations, eliminating the need for a human operator to physically follow and manually control the crane, thus removing safety hazards while maintaining real-time control capability.
Solution Approach 2:
The patent replaces the mechanical manual control system with an optical-based automatic control system. Instead of a person physically following the crane and manually operating controls, the system uses laser beams and optical receivers to automatically track and control crane position, substituting mechanical human operation with an automated optical-mechanical system that eliminates safety risks to operators.
3Measurement precision
If the laser is mounted on a fixed structure, then the laser beam does not skew and accurate distance measurements are obtained, but additional installation on walls or fixed surfaces is required
Solution Approach 1:
The patent extracts the laser from the moving crane system and places it on a fixed external structure, separating the stationary measurement reference from the moving target. This extraction allows the laser to remain stationary and maintain accurate alignment while the crane and reflector move independently, achieving precise measurements without the complexity of mounting and aligning lasers on moving parts.
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 maintains accurate crane positioning, reduces the risk of accidents by preventing skewing, and enhances safety and efficiency in large manufacturing facilities by ensuring the crane remains square relative to the rails and objects.
Implementation Method 1
the laser generates a laser beam that is directed towards a reflector mounted on a wall or other fixed surface in the facility. The laser beam directed to the reflector generates a response that is reflected back to an optical receiver in the laser. The laser is then able to determine a distance based on the reflected beam.
Data Source
AI summary
A laser positioning system is used in association with a crane within a manufacturing facility. The laser positioning system includes a laser source that is mounted on an immovable or non-moving wall or surface in the manufacturing facility. The laser source on the wall or surface ensures that the laser beam does not skew out of square relative to the movement of the crane to various locations in the facility.