Hoist Rope Maturity Prediction via Load and Bending Monitoring
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Solution Overview
Problem
Existing hoist systems lack reliable methods to determine the real service life of ropes, leading to potential failure due to undetected stress and bending changes, which can result in unsafe operation and premature damage.
Innovation Solution
Incorporating a rope bending change measuring device and a forecasting device with a data memory and computer unit to record load and bending changes, allowing for the calculation of theoretical rope storage readiness and predicting the remaining service life based on load spectra and bending cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If rope replacement is based on fixed maintenance intervals, then operational simplicity is maintained, but actual service life cannot be accurately determined leading to premature or delayed replacement
Solution Approach 1:
The system performs preliminary monitoring and data collection during rope operation, accumulating load and bending cycle information before replacement is needed. This allows accurate service life determination to be made in advance based on actual usage conditions rather than fixed intervals.
Solution Approach 2:
The monitoring system automatically tracks rope usage parameters and calculates remaining service life without requiring external intervention. The system serves itself by continuously monitoring its own operational state and providing replacement timing recommendations.
2Reliability
If fixed maintenance intervals are used, then operational simplicity is maintained, but rope safety cannot be ensured due to varying actual stress conditions
Solution Approach 1:
The system continuously monitors actual rope load and bending cycles, providing feedback on the true operational conditions. This feedback loop allows the maintenance schedule to be adjusted based on actual rope stress exposure, ensuring safety while adapting to real-world usage patterns.
Solution Approach 2:
The system changes the maintenance parameter from fixed time intervals to dynamic usage-based parameters (load spectra and bending cycles). This allows the maintenance schedule to adapt to actual operational conditions, improving safety by reflecting true rope stress levels.
3Loss of time
If rope replacement is delayed beyond actual service life, then maintenance costs are reduced, but rope failure risk increases due to undetected stress accumulation
Solution Approach 1:
The system performs preliminary assessment of rope condition by monitoring cumulative load and bending cycles, predicting remaining service life before actual failure occurs. This allows planned replacement at the optimal time rather than waiting for failure symptoms.
Solution Approach 2:
The system replaces mechanical inspection methods with electronic monitoring and computer-based analysis. Sensors continuously measure load and bending, and computer calculations predict service life, providing more accurate and timely replacement timing than traditional mechanical inspection.
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 timely replacement of ropes and other components, preventing damage and ensuring safe operation by accurately forecasting the end of service life, thereby enhancing maintenance intervals and overall system reliability.
Implementation Method 1
the force is measured using at least one strain gauge (SG)
Data Source
Figure 1~3
Figure 4
AI summary
The invention relates to a lifting mechanism (1), e.g., of a hoist, with one or more ropes (4), one or more rope drums (3), and one or more drives (2). The invention further relates to a method for determining the theoretical rope maturity. For this purpose, a load measuring device (6; 10) is proposed for determining the load acting on the at least one rope (4), wherein the lifting mechanism (1) further comprises a rope bending change measuring device for determining the rope bending changes of the at least one rope (4) and a prediction device with a data storage unit and a computing unit for determining the theoretical rope maturity of the at least one rope (4) based on the data from the load measuring device (6; 10) and the rope bending change measuring device.