Hoist Control Unit for Load Slip and Motor Overheating Prevention
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Solution Overview
Problem
Conventional hoist brake assemblies are prone to failure during prolonged use or overloading, leading to potential free falls and motor overheating, posing hazards and requiring a control unit to manage load slip conditions effectively.
Innovation Solution
A control unit with a processor and memory that computes positions and operates the hoist to selectively lift and lower loads between defined positions based on feedback from encoders or toothed wheel assemblies, overriding manual control to automated operation to prevent uncontrolled falls and maintain a safe work area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the brake assembly is used to hold the load in overhang position, then the load can be supported stably, but the brake assembly may fail during prolonged usage or overloading causing free fall
Solution Approach 1:
The control system continuously monitors brake assembly status and detects slip conditions before complete failure occurs. When a slip condition is detected, the system proactively activates the motor to compensate for brake failure and prevent load free fall, rather than waiting for actual failure
Solution Approach 2:
The system uses feedback from encoders or toothed wheel assemblies to continuously monitor load position and detect slip conditions. This feedback mechanism enables real-time detection of brake assembly performance degradation and triggers automated compensation actions
2Reliability
If the motor operates at zero speed to hold the load unattended, then the load position is maintained, but the motor gets heated up quickly and may burn out
Solution Approach 1:
Instead of continuous zero-speed operation, the system uses periodic motor activation to compensate for brake failure. The motor operates intermittently to adjust load position, allowing cooling periods between operations and preventing overheating while maintaining load support
Solution Approach 2:
The control system automatically manages motor operation to prevent overheating. When slip conditions are detected, the system self-regulates motor activation and deactivation based on load position feedback, eliminating the need for continuous motor engagement
3Ease of operation
If manual control is used for hoist operation, then the operator has direct control, but the operator cannot respond automatically to brake failure or slip conditions
Solution Approach 1:
The system incorporates feedback from encoders or toothed wheel assemblies that continuously monitor load position and communicate with the control unit. This automated feedback mechanism enables detection of slip conditions without operator intervention and triggers automatic compensation actions
Solution Approach 2:
The control unit acts as an intermediary between the operator and the hoist system. It monitors brake assembly status and motor operation, automatically intervening when slip conditions are detected to compensate for brake failure, while still allowing operator control when conditions are normal
Data Source
AI summary
The present disclosure relates to a control unit for controlling operation of a hoist in a load slip condition. The hoist may include a motor coupled to a winding drum for lifting and lowering a load. The control unit may include a processor and a memory communicatively coupled to the processor. The memory may store processor executable instructions, which, on execution, cause the processor to operate the hoist for selectively lifting and lowering a load between a first position and a second position upon detecting a load slip condition. The processor may operate the hoist based on parameters pertaining to transport of the load. The control unit may be configured to reciprocate the load in a load slip condition to prevent overheating and failure of a motor, thereby preventing a fall of the load in a work area.