Hoist Group Operation Overload Protection via Load Monitoring
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Solution Overview
Problem
Existing methods for operating multiple lifting gears in group operations fail to reliably prevent overload and potential crashes, especially when transitioning from synchronous to individual operations, as they cannot detect and prevent overloading in deactivated hoists.
Innovation Solution
Implementing a method where load values for each hoist are continuously monitored and compared to permissible thresholds, even after transitioning to individual operations, to prevent overloading and allowing a return to synchronous operation if an overload is detected, without requiring additional hardware or complex controllers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hoists are deactivated during individual operation after synchronous operation, then operational flexibility is improved, but safety deteriorates due to undetected overload in deactivated hoists
Solution Approach 1:
The patent implements a feedback mechanism where the controller of an activated hoist receives load value information from deactivated hoists and compares it against permissible threshold values. This feedback loop enables the activated hoist to detect potential overload conditions in deactivated hoists and prevent operations that would cause such overload, thereby maintaining safety while allowing operational flexibility.
Solution Approach 2:
The controller of the activated hoist acts as an intermediary that monitors and coordinates operations between activated and deactivated hoists. It receives load value data from the deactivated hoist, evaluates it against safety thresholds, and controls the activated hoist's operations accordingly, preventing unsafe conditions while enabling flexible operation modes.
2Reliability
If overload monitoring is implemented for deactivated hoists, then safety is improved, but device complexity increases
Solution Approach 1:
The controller of the activated hoist is designed to perform multiple functions: it controls its own hoist operations and simultaneously monitors load values from deactivated hoists, compares them against threshold values, and prevents operations that would cause overload. This multi-functionality approach avoids adding separate monitoring devices while enhancing safety.
Solution Approach 2:
The activated hoist's controller performs self-service by using its own processing capabilities to monitor and evaluate load conditions of deactivated hoists. Rather than requiring external monitoring systems, the controller leverages its existing computational resources to execute safety monitoring functions, thereby avoiding additional hardware complexity.
3Reliability
If load values are continuously monitored and compared for each hoist, then overload protection is improved, but measurement precision requirements increase
Solution Approach 1:
The patent applies local quality by implementing threshold-based comparison at the controller level rather than requiring high-precision continuous measurement throughout the system. Each hoist's load sensor provides local load value data, and the activated hoist's controller performs local comparison against predetermined threshold values, ensuring adequate protection without demanding system-wide high-precision measurement infrastructure.
Data Source
AI summary
A method and assembly for operating at least two lifting gears in a group operation, where each lifting gear has a hoist via which a respective cable or chain can be raised or lowered. The hoists are first operated in a synchronous operating mode to perform a common lifting procedure to move a load supported by the hoists. At least one of the hoists involved in the common lifting procedure is then deactivated to switch from the synchronous operation into an individual operation or a multi-operation, with at least one of the hoists remaining activated to carry out a lifting or lowering process relative to each deactivated hoist. A load value is then determined for the at least one deactivated hoist and compared to a predetermined threshold value of the at least one deactivated hoist.