Asynchronous Free-Fall Winch Control for Construction Mast
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing construction machines with two rope winches for upward and downward movement of tools or loads require synchronous operation, which can be time-consuming and inefficient, especially when handling heavy loads, as they need to manage the entire weight jointly.
Innovation Solution
Incorporating a free fall winch that can operate asynchronously with a force-locking winch, allowing the hoist rope to be lowered at free-fall speed while maintaining control through a pulley block and free fall brake, enabling efficient and safe movement of loads by allowing different winding speeds for the two winches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two rope winches are operated synchronously to move heavy loads, then safety is improved, but operation time increases and efficiency decreases
Solution Approach 1:
The system dynamically switches between synchronous operation mode (for safety-critical phases) and asynchronous operation mode (for efficiency-critical phases). The controller enables dynamic adjustment of winch operation modes based on operational requirements, allowing the system to optimize between safety and efficiency at different times during the lifting/lowering process.
Solution Approach 2:
The operational parameters of the rope winches are changed from fixed synchronous operation to variable asynchronous operation. By modifying the control parameter from synchronized speed to independent speed control with controller coordination, the system achieves both safety through controlled operation and efficiency through optimized timing.
2Reliability
If two rope winches are operated synchronously, then controlled lowering is achieved, but the process becomes time-consuming
Solution Approach 1:
The lowering process is divided into periodic phases: initial controlled lowering (synchronous mode for stability), intermediate free-fall lowering (asynchronous mode for speed), and final controlled stopping (synchronous mode for precision). This periodic switching between operation modes optimizes both control and time efficiency.
Solution Approach 2:
The system skips the time-consuming controlled lowering phase by transitioning to asynchronous free-fall mode after initial positioning. The controller manages the transition to allow rapid descent through the majority of the travel distance, then returns to controlled mode only for the final positioning, thereby reducing total time while maintaining control where necessary.
3Productivity
If rope winches operate with different winding speeds asynchronously, then efficiency improves, but coordination difficulty increases
Solution Approach 1:
The controller implements feedback mechanisms to monitor the position, speed, and tension of both rope winches in real-time. This feedback enables the controller to automatically adjust winding speeds and maintain proper coordination between the asynchronously operating winches, eliminating the need for complex manual coordination while preserving efficiency benefits.
Solution Approach 2:
The controller acts as an intermediary between the two asynchronously operating rope winches, mediating their coordination through automated control algorithms. This intermediary function simplifies the overall system complexity by centralizing the coordination logic in the controller rather than requiring complex mechanical or operational coordination mechanisms.
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 solution enables quick and efficient lowering of heavy loads at free-fall speed while ensuring controlled operation, allowing for safe and efficient upward and downward movement of tools or loads, even when operating asynchronously, thus enhancing operational efficiency and safety.
Implementation Method 1
The free-wheel release or winding out can thereby be produced by the gravitational force of a tool or a load which can be connected to the hoist rope by means of a lifting element
Implementation Method 2
at least one first rope winch is designed as a free fall winch, wherein the hoist rope can be lowered with free-wheeling
Implementation Method 3
maintaining control through a pulley block and free fall brake
Data Source
AI summary
The invention relates to a construction machine having a mast and a lifting element which can be moved up and down along the mast with a hoist rope. The hoist rope can be activated by means of two rope winches. At least one first rope winch is designed as a free fall winch, wherein the hoist rope can be lowered in free fall. To lower the hoist rope a controller is provided, with which the first rope winch, which is designed as a free fall winch, can be switched into a free fall mode. Meanwhile, a second rope winch is operated in force-locking manner.