Hoisting Rope Condition Tracking with In-Operation Signal Referencing
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Solution Overview
Problem
Existing methods for determining the condition of lifting ropes in systems like cranes and industrial plants require downtime for maintenance, which is not feasible for continuously operating facilities.
Innovation Solution
A method involving a sensor device with multiple sensor units that generate and analyze sensor signals to create and update reference characteristics of the lifting rope's condition in real-time, allowing for continuous operation without interruptions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional methods for determining lifting rope condition are used, then maintenance can be performed, but the system requires downtime and maintenance interruptions
Solution Approach 1:
The system performs preliminary monitoring and assessment of the lifting rope condition during operation, detecting wear and damage before they become critical. The reference characteristic is established and updated in advance, enabling predictive maintenance planning without forcing unplanned downtime.
Solution Approach 2:
The monitoring system operates continuously during lifting system operation, with the sensor unit constantly generating sensor signals as the lifting rope moves past it. The evaluation unit continuously processes these signals and updates the reference characteristic without interruption, maintaining both system operation and monitoring function simultaneously.
2Measurement precision
If the lifting rope is monitored frequently to detect wear and damage, then reliability improves, but the complexity of the monitoring system increases
Solution Approach 1:
The system extracts only the essential monitoring function from a complex inspection system. By using a single sensor unit that detects changes in the lifting rope's physical properties (such as diameter, texture, or magnetic characteristics), the system achieves accurate condition assessment without requiring multiple sophisticated sensors or complex inspection equipment.
Solution Approach 2:
The evaluation unit creates a digital reference characteristic that copies the baseline condition of the lifting rope. This reference model is then compared against subsequent measurements to detect deviations indicating wear or damage. The copying approach simplifies the monitoring system by replacing physical inspection templates with a digital reference that can be continuously updated and compared.
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 monitoring and analysis of lifting rope condition, predicting wear and potential failures, thus ensuring the system remains operational without downtime and allowing for proactive maintenance.
Implementation Method 1
an inductive sensor, which is positioned such that a magnetic field generated by the inductive sensor, extending at least partially over the elevator rope, is evaluated by a control device
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
The invention relates to a method for determining a rope condition of a hoisting rope (20) and a hoisting system (10), wherein a sensor device (25) with at least a first sensor unit (70), a data memory (35) and a hoisting rope (20) are provided, wherein the hoisting rope (20) is moved past the first sensor unit (70) over an available rope length, wherein the first sensor unit (70) generates a first sensor signal, wherein a first signal profile of the first sensor signal is determined as a function of the first rope position (p1(I)) as a first reference characteristic (100) of the hoisting rope (20), wherein a rope section (110) of the hoisting rope (20) is measured at the first sensor unit (70), wherein the first sensor unit (70) generates a second sensor signal as a function of a second rope position (p2(I)) of the hoisting rope (20), wherein a second signal profile (120) is determined as a function of the second rope position (p2(I)) is determined,wherein the second signal curve (120) is assigned to a subsection (116) of the first reference characteristic (100), wherein the subsection (116) of the first reference characteristic (100) assigned to the second signal curve (120) is updated by the second signal curve (120), wherein the updated reference characteristic is stored as a second reference characteristic (125).