Load-Borne Acceleration Sensor for Stage Load Diagnosis
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Solution Overview
Problem
Current load transportation systems lack an independent and universal measuring system capable of accurately recording safety-relevant properties and diagnosing devices, especially during accidents or faulty operations, as conventional sensors are not designed to measure accident loads and cannot determine the behavior of loads without a fixed connection.
Innovation Solution
A measuring system comprising an acceleration sensor attached directly to the load, a monitoring system, and an evaluation system that measures and documents accelerations during normal and faulty operations, allowing for the determination of accident loads and providing a comprehensive diagnosis, including the analysis of load behavior and safety device performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional sensors are used in load transportation systems, then the system can measure normal operation parameters, but the sensors cannot accurately measure accident loads or determine load behavior during faults
Solution Approach 1:
The patent segments the measurement function by using multiple independent acceleration sensors positioned at different locations on the load (e.g., top and bottom surfaces). This segmentation allows each sensor to independently measure local acceleration events, ensuring that at least one sensor captures accident loads even when the load orientation changes or lifts off from the suspension.
Solution Approach 2:
The patent introduces an intermediary processing unit that receives data from multiple acceleration sensors and combines their measurements. This intermediary system reconstructs the complete load behavior by merging partial measurements from different sensor locations, enabling accurate determination of accident loads and load orientation even when individual sensors have limited visibility.
2Adaptability or versatility
If the load has no fixed connection to the suspension, then the load can move freely, but the machine's sensors cannot measure force or acceleration when the load lifts off
Solution Approach 1:
Instead of attaching sensors to the suspension system to measure load forces indirectly, the patent inverts the approach by attaching acceleration sensors directly to the load itself. This allows the load to move freely without fixed connection while the sensors on the load continue to measure its acceleration and orientation directly, regardless of whether it is in contact with the suspension.
Solution Approach 2:
The patent replaces the mechanical force measurement system (sensors on the suspension measuring tension/compression) with an inertial measurement system (acceleration sensors on the load). This substitution allows measurement of load behavior through acceleration data rather than mechanical force transmission, enabling accurate measurement even when the load is not in contact with the suspension.
3Reliability
If an independent measuring system is introduced, then comprehensive safety diagnosis is enabled, but the system complexity increases
Solution Approach 1:
The patent designs the acceleration sensors and processing unit to serve multiple functions: measuring normal operation parameters, detecting accident loads, determining load orientation, assessing safety device performance, and validating design assumptions. This multi-functionality reduces the need for separate specialized sensors for each measurement task, thereby limiting the increase in system complexity.
Solution Approach 2:
The patent changes the measurement parameter from force (measured by conventional load cells) to acceleration (measured by acceleration sensors). This parameter change enables a single sensor type to measure multiple physical quantities (force, orientation, impact severity) through different data processing approaches, reducing system complexity while expanding measurement capabilities.
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 the determination of accident loads and safety assessments, improving safety by identifying and addressing security deficiencies, and providing a universal, independent solution for existing and new load transportation systems, with the ability to measure high accelerations and determine physical variables like force and speed.
Implementation Method 1
The monitoring system has an acceleration sensor for detecting the acceleration of the load
Data Source
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AI summary
Revealed is a measuring system for diagnosing load-carrying equipment, comprising an evaluation system and a monitoring system. The monitoring system can detect the acceleration of the load. It is designed to be directly attached to the load or a load-bearing device. The measuring system is configured to measure accelerations during both normal and fault operation. This system is used in stage technology. The system's operation involves a first step in detecting the acceleration. In a second step, the acceleration values are converted into other physical quantities, and in a third step, they are compared with the values obtained from conventional sensors.