Hoist Load Detection via Distance Sensor
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Solution Overview
Problem
Existing hoist systems face challenges in detecting overloads, particularly internal overloads, due to high design complexity and costly bearing constructions required for load detection, which also fail to account for space efficiency and retrofittability.
Innovation Solution
A structurally simple and cost-effective load detection system using a distance sensor attached to the hoist housing, which measures the distance change between a measurement object and the sensor, allowing continuous load determination without mechanical wear, and is retrofittable to existing hoists.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a bearing support with bearing and sensor is added to detect load, then load detection capability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts the load detection function from the complex bearing support structure and relocates it to a simple distance sensor mounted on the housing. The distance sensor measures the position of a mark on the shaft, which changes with load-induced shaft displacement, thereby obtaining load information without requiring a bearing support structure.
Solution Approach 2:
The patent replaces the mechanical bearing support structure with an optical/electronic distance sensor system. Instead of using mechanical sensors within a bearing to detect load, the system uses a distance sensor to measure shaft position changes caused by load, substituting mechanical measurement with optical/electronic measurement.
2Reliability
If a bearing support with sensor is installed for load detection, then overload detection is improved, but installation space and manufacturing cost increase
Solution Approach 1:
The patent extracts the essential detection function from the complex bearing support and implements it through a simple distance sensor mounted on the housing. This extraction eliminates the need for costly bearing structures while maintaining the ability to detect shaft displacement caused by overload conditions.
Solution Approach 2:
The patent uses a simple, inexpensive distance sensor instead of a complex, expensive bearing support structure. The distance sensor is mounted on the housing and measures shaft position changes, providing a cost-effective solution that is easier to manufacture and install.
3Measurement precision
If mechanical connection or electrical cable is used between load detection point and evaluation unit, then load detection is enabled, but device complexity increases
Solution Approach 1:
The patent replaces mechanical connections (levers, pulleys) and electrical cables with a direct electronic measurement system. The distance sensor electronically measures shaft position changes and transmits data to the evaluation unit without requiring mechanical linkages or cable connections between the load detection point and evaluation unit.
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
Enables continuous, accurate overload detection with reduced design complexity and installation space requirements, improving safety and cost-effectiveness while allowing easy retrofitting of existing hoists.
Implementation Method 1
a distance sensor (7) which is designed inductively, capacitive or optical
Data Source
Figure 1a~1c
Figure 2~3
Figure 4~5
AI summary
The invention relates to a lifting device, in particular a rope or chain hoist, with a lifting mechanism for raising and lowering a load, comprising a housing (1) that accommodates a motor connected to a gearbox (2) that drives a shaft (21) rotatably mounted in the housing (1) and on which a reel (3) is arranged, which accommodates a rope or chain (4) that is guided through an opening in the housing (1) and has a load hook (41) at its end, wherein a measuring device for continuously detecting the load on the load hook (41) is provided in the housing (1), wherein the measuring device comprises a distance sensor (7) that is attached to the housing (1) at a defined distance to a measuring object connected to the shaft (21) or the housing (1) when the rope or chain (4) is unloaded.