Hoist Control System for Dipper Drop Mitigation
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Solution Overview
Problem
Industrial machines like electric rope shovels experience uncontrolled dipper drops due to machine faults or operator errors, leading to potential damage and injury, and require immediate corrective actions to prevent further harm and downtime.
Innovation Solution
A control system that monitors and compares actual hoist characteristics with requested parameters, adjusting hoist torque and setting brakes as necessary to mitigate dipper drop conditions, ensuring the machine's safe operation and minimizing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the industrial machine shuts down to investigate dipper drop conditions, then the cause can be determined, but production is lost and logistics costs increase
Solution Approach 1:
The control system performs preliminary detection and analysis of dipper drop conditions continuously during operation. By identifying the condition before it causes damage or requires shutdown, the system can take corrective action while maintaining operation, thus preventing productivity loss while ensuring reliability.
Solution Approach 2:
The system continuously monitors hoist torque, speed, and dipper position parameters, comparing actual values against expected ranges. This feedback loop enables real-time detection of dipper drop conditions and automatic corrective action, allowing the machine to maintain reliable operation without shutting down for investigation.
2Reliability
If the controller continuously monitors and adjusts hoist parameters to prevent dipper drops, then safety is improved, but control system complexity increases
Solution Approach 1:
The control system performs multiple functions using existing components: it monitors hoist torque, speed, and dipper position; compares actual values against expected ranges; detects dipper drop conditions; and executes corrective actions. This multi-functionality achieves high safety without proportionally increasing complexity, as the same control architecture handles all monitoring and response tasks.
Solution Approach 2:
The system automatically detects dipper drop conditions and executes corrective actions without requiring external intervention or complex additional hardware. The control system serves itself by using its existing sensors and actuators to monitor its own state and respond to anomalies, achieving safety improvement without significant complexity increase.
3Reliability
If the system responds quickly to dipper drop conditions, then damage and injuries are prevented, but the machine may experience frequent torque adjustments
Solution Approach 1:
The control system applies partial corrective torque adjustments rather than maximum force. By using moderate, progressive torque modifications rather than abrupt maximum corrections, the system prevents damage through timely intervention while minimizing the harmful impacts of torque adjustments on the mechanical system.
Solution Approach 2:
The system continuously monitors hoist parameters within expected ranges and prepares corrective actions before actual dipper drop damage occurs. By detecting early signs of dipper drop and applying gradual torque adjustments in advance, the system cushions against the harmful effects of sudden full-correction torque shocks, preventing damage while minimizing adjustment impacts.
Data Source
AI summary
An industrial machine that includes a dipper, a user interface, a sensor, a hoist actuator, and a controller. The user interface is operable to generate a first signal related to a requested characteristic of the industrial machine. The sensor is operable to generate a second signal related to an actual characteristic of the industrial machine. The hoist actuator has at least one operating parameter. The controller is configured to receive the first signal related to the actual characteristic, receive the second signal related to the requested characteristic, compare the requested characteristic to the actual characteristic to detect a dipper drop condition, and modify a setting of the at least one operating parameter of the hoist actuator after the dipper drop condition is detected. The dipper drop condition is detected after the requested characteristic does not match the actual characteristic