Hoist Controller Multi-Speed Control via Hall Sensor

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Solution Overview

Problem

Conventional hoist controllers using relay switches are limited to two-stage speed control, leading to short service life, high material and labor costs, weight, and noise issues, making them difficult to miniaturize and efficient.

Innovation Solution

A controller for an electric hoist using an inverter-driven motor with adjustable lift up and down buttons, a magnet body, and a Hall sensor to vary motor speed through adjustable resistance values based on detected magnetic flux density, enabling multi-stage speed control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a relay switch is used for speed control, then the hoist can be controlled, but the service life is short and the structure is complex

Engineering Contradiction:

Improveservice lifeVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical relay switch system with an electronic inverter control system. The inverter uses electronic components such as IGBTs (Insulated Gate Bipolar Transistors) and microprocessors to control motor speed, eliminating the need for mechanical relay switches. This substitution provides longer service life due to no mechanical wear, and reduced structural complexity through integrated electronic control circuits.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the control parameter from discrete relay switching to continuous inverter-based frequency and voltage control. The inverter adjusts the motor speed by varying the frequency and voltage of the power supply, enabling smooth multi-stage speed control without the mechanical wear and complexity associated with relay switches.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If a relay switch is used for speed control, then the hoist can be controlled, but the material and labor costs are high

Engineering Contradiction:

Improveproduction costVSAvoidservice life

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If a relay switch is used for speed control, then the hoist can be controlled, but the wiring is complicated

Engineering Contradiction:

Improvewiring complexityVSAvoidmanufacturing efficiency

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The patent merges the control functions into a single inverter unit that integrates the control circuitry, power conversion, and motor control in one device. This consolidation eliminates the need for separate relay switches and their associated wiring, significantly reducing wiring complexity and improving manufacturing efficiency through standardized integration.

Inventive Principle:

Principle #5Merging (Combining)

4Use of energy by moving object

If a relay switch is used for speed control, then the hoist can be controlled, but the electric power consumption is high

Engineering Contradiction:

Improveelectric power consumptionVSAvoidservice life

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

5Object-affected harmful factors

If a relay switch is used for speed control, then the hoist can be controlled, but noise is severely generated

Engineering Contradiction:

Improvenoise levelVSAvoidservice life

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

6Adaptability or versatility

If only two-stage speed control is implemented, then the controller is simple, but the operational versatility is limited

Engineering Contradiction:

Improvespeed control rangeVSAvoidcontroller complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

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

The solution allows for semi-permanent operation, reduced size and weight, lower production costs, simplified wiring, reduced noise, and improved maintenance accessibility by enabling multi-stage speed control of the hoist.

Implementation Method 1

a Hall sensor disposed to correspond to the magnet body so as to detect a descending degree of the magnet body being pressed by the lift up button or the lift down button

Methodology Applied

Scientific EffectHall effect: Hall Effect

Data Source

PatentUS10781088B2Controller for hoist capable of multi-speed control and hoist including the same controller

Publication Date: 2020.09.22 DAESAN INOTEC

AI summary

Disclosed herein is a controller of a hoist. The controller of the hoist includes a lift up button which is adjustable in a pressed degree; a lift down button which is adjustable in a pressed degree; a lift up switch disposed below the lift up button so as to be immediately operated when the lift up button is pressed; a lift down switch disposed below the lift down button so as to be immediately operated when the lift down button is pressed; a magnet body connected to both of the lift up button and the lift down button and disposed to descend during a pressing operation of the lift up button or the lift down button; and a Hall sensor disposed to correspond to the magnet body so as to detect a descending degree of the magnet body being pressed by the lift up button or the lift down button.