Grapple Hoist Control for Fill Volume Optimization
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Solution Overview
Problem
Current methods for controlling the fill volume of crane grapples are inefficient due to varying factors such as grapple entry angle and material compactness, leading to suboptimal filling and potential overloading, which can result in crane damage.
Innovation Solution
A method that adjusts the grapple hoist height and speed using a control device with a mathematical model to optimize the fill volume, allowing for dynamic adjustments based on real-time sensor data and operator input to achieve the desired load without overloading the crane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the grapple is filled to maximum capacity, then the productivity and travel efficiency of the crane is improved, but the risk of overloading the crane structure increases
Solution Approach 1:
The control device continuously monitors the actual fill volume of the grapple and compares it with the maximum allowable load, automatically adjusting the hoist height to maintain optimal filling while preventing overloading. This closed-loop feedback system ensures both high productivity and structural safety.
Solution Approach 2:
The system dynamically adjusts the grapple hoist height as a controllable parameter during the closing process, optimizing the fill volume based on real-time conditions such as material compactness and grapple entry angle, thereby achieving maximum productive capacity without exceeding structural limits.
2Loss of time
If the grapple fill volume is increased to optimize crane utilization, then the travel distance and productivity are improved, but the crane may become overloaded
Solution Approach 1:
The control device calculates and adjusts the grapple hoist height in advance during the closing process, based on predicted fill volume and material properties, ensuring the grapple is optimally filled before lifting begins, thus maximizing travel efficiency while maintaining safe load limits.
Solution Approach 2:
Real-time monitoring of fill volume and load conditions provides continuous feedback to the control system, which automatically adjusts the hoist height to maintain optimal filling without exceeding the crane's load capacity, balancing productivity and safety.
3Manufacturing precision
If the grapple hoist height is adjusted during closing, then the fill volume control precision is improved, but the device complexity increases
Solution Approach 1:
The control device performs multiple functions: it monitors fill volume, calculates optimal hoist height adjustments, controls the hoist mechanism, and prevents overloading. By integrating these functions into a single multi-functional control system, the patent achieves precise fill volume control while minimizing the overall device complexity.
Solution Approach 2:
The control device automatically determines the optimal grapple hoist height based on sensor inputs and pre-stored models, without requiring manual intervention or complex external control systems. This self-service capability achieves precise fill volume control while keeping the control system relatively simple.
Data Source
AI summary
A method for controlling the fill volume of a grapple, such as a bulk-material crane grapple which includes at least one hoist-and-closure unit, may include adjusting the fill volume of the grapple is during the grapple closure process by adjusting/controlling the grapple hoist height. The grapple hoist speed and/or grapple hoist height may be the controlling parameter for the adjustment of the fill volume of the grapple.