Automated Head Frame Coupling System for Spreader Alignment
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Solution Overview
Problem
The existing manual engagement systems for coupling head frames and spreaders are inefficient, particularly during maintenance or switching between single and twin spreader arrangements, leading to increased downtime and operational challenges.
Innovation Solution
An automated system and method for coupling a head frame to a spreader, utilizing a sheave assembly, mutually cooperating engagement devices, an actuator for connecting transmission connectors, and a registration device to ensure proper alignment and power communication, allowing for semi-automated operation and reduced downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual engagement is used for coupling head frame and spreader, then device complexity is reduced, but productivity and operational efficiency deteriorate due to increased downtime during maintenance and switching operations
Solution Approach 1:
The coupling system performs its own alignment and connection functions through the registration device that automatically guides the transmission connectors into proper engagement position, eliminating the need for external manual intervention while maintaining operational efficiency
Solution Approach 2:
The patent replaces purely manual mechanical engagement with an automated system incorporating actuators that drive transmission connectors, while the registration device provides mechanical guidance and registration to ensure proper alignment during the automated coupling process
2Productivity
If automated engagement system is implemented, then productivity and operational efficiency improve, but device complexity increases due to additional actuators and registration devices
Solution Approach 1:
The registration device serves multiple functions: it registers the relative position of head frame and spreader, guides the transmission connectors into alignment, and prevents premature engagement of electrical connectors, thereby reducing the need for separate alignment and positioning mechanisms
Solution Approach 2:
The registration device performs preliminary alignment and positioning of the transmission connectors before the actuators complete the engagement, ensuring that connectors are properly aligned prior to connection and preventing premature electrical connector engagement
3Speed
If transmission connectors are connected before proper alignment, then coupling speed increases, but reliability deteriorates due to misalignment and potential damage
Solution Approach 1:
The registration device provides feedback on the relative position and alignment status of the head frame and spreader, enabling the control system to determine when proper alignment has been achieved before permitting transmission connector engagement, thus ensuring reliability while maintaining speed
Data Source
AI summary
A system for mounting a head frame to a spreader comprising: a sheave assembly connecting the head frame to a crane so as to permit the lowering of said head frame; mutually cooperating engagement devices for coupling the head frame and the spreader; an actuator arranged to connect mutually engageable transmission connectors on the head frame and spreader; and; a registration device for registering the coupling of the head frame and the spreader; wherein the registration device is arranged to prevent engagement of the transmission connector until said head frame and spreader are coupled.