Light Grid System for Rope Machinery Slack Detection
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Solution Overview
Problem
Conventional slack rope detection modules in large rope machinery, such as dragline excavators, fail to detect slack ropes early enough to prevent damage and are prone to false positives, leading to inefficiencies and machine downtime due to their limited positioning and single-beam configuration.
Innovation Solution
A light grid system with multiple light grid assemblies positioned near the rope drums, emitting and receiving light beams to detect slack ropes and transmit signals to a control module for timely intervention, allowing for adjustable placement to reduce false positives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single beam photometric transmitter/receiver module is positioned close to the top of the deck, then the module has easier installation and lower complexity, but it can only detect the most severe slack rope conditions and not early enough to prevent damage
Solution Approach 1:
The system divides the detection function into multiple modules: a photometric transmitter module positioned near the drum for early detection, and a photometric receiver module positioned elsewhere. This segmentation allows each module to be optimally positioned for its specific function, resolving the contradiction between early detection capability and installation complexity.
Solution Approach 2:
The patent introduces a control module as an intermediary that receives signals from the photometric receiver and processes the detection data. This intermediary component enables the system to interpret the optical signals and trigger appropriate responses, bridging the gap between the physical detection elements and the damage prevention function.
2Reliability
If a single beam photometric module is used, then the device complexity is reduced, but it may not detect slack ropes that are out of the direct line of the single beam
Solution Approach 1:
The detection system is segmented into multiple photometric transmitter modules and receiver modules arranged in a grid pattern. This segmentation allows the system to monitor multiple spatial zones simultaneously, improving detection accuracy without requiring an overly complex centralized design.
Solution Approach 2:
The patent transitions from a single-beam (one-dimensional) detection approach to a grid arrangement of multiple beams (two-dimensional coverage). This dimensional change allows the system to detect slack ropes across a broader spatial area, capturing conditions that would fall outside a single beam's line of sight.
3Loss of time
If conventional detection modules are positioned away from the drum, then the modules have easier access and installation, but they detect only the most severe slack rope conditions
Solution Approach 1:
The photometric transmitter module is positioned close to the drum in advance, before any slack rope condition develops. This preliminary positioning allows the system to detect the earliest signs of slackness, preventing the condition from worsening to a damaging level. The early detection capability compensates for the increased installation complexity.
4Reliability
If conventional detection modules are not adjustable, then the device complexity is reduced, but the module cannot be easily corrected in response to false positives
Solution Approach 1:
The patent introduces adjustability into the photometric module system, allowing operators to dynamically modify the position and sensitivity of the transmitter and receiver modules. This dynamic capability enables the system to adapt to different operating conditions and correct false positives, improving reliability while maintaining reasonable ease of adjustment through standardized mounting interfaces.
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 light grid system effectively identifies slack ropes more quickly and accurately, reducing machine component damage and downtime by enabling early detection and adjustable positioning to minimize false alerts.
Implementation Method 1
at least a first sensor configured to emit one or more light beams, and at least a second sensor configured to receive one or more light beams
Data Source
AI summary
A light grid system for rope machinery is provided. The light grid system includes one or more light grid assemblies, including one or more sensor frames configured to be coupled to one or more post assemblies and configured to mount adjacent to one or more rope drums. The light grid assemblies also include one or more sensors coupled to the sensor frames, at least a first sensor configured to emit one or more light beams, at least a second sensor configured to receive the light beams. The light beams are positionable a predetermined distance away from the ropes, and the light grid assemblies are configured to transmit a signal to a control module when the light beams are obstructed.