Automated Load Cycle Detection in Handling Machines
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Solution Overview
Problem
Existing systems for detecting load cycles in handling machines require manual interaction, leading to inaccuracies and unreliable detection due to incorrect or missing trigger thresholds, and are prone to false recordings, especially when the payload weight is significantly less than the weight of the handling device and slinging gear.
Innovation Solution
An automated system that uses load change detection and position detection to identify load cycles based on the output signals from a lifting force measuring device, eliminating the need for manual threshold settings by determining the start of a new load cycle when the load is moved a predetermined distance from the pick-up point and considering load speed to filter out fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual threshold setting is used for load cycle detection, then the system can operate with simple hardware, but the detection reliability deteriorates due to incorrect or missing trigger thresholds
Solution Approach 1:
The system automatically determines trigger thresholds and detects load cycles without manual intervention. The control unit autonomously processes signals from the lifting force measuring device and position detection system to identify load cycle start and end points, eliminating the need for manual threshold setting while maintaining high detection reliability.
Solution Approach 2:
The system performs preliminary detection of load changes and position variations before finalizing load cycle identification. By continuously monitoring lifting force and position data, the system prepares and validates trigger conditions in advance, ensuring accurate load cycle detection without requiring manual threshold configuration.
2Reliability
If high load thresholds are used to avoid faulty detection, then false recordings are reduced, but the measurement precision deteriorates for small payloads
Solution Approach 1:
The system dynamically adjusts detection sensitivity based on the actual lifting force measurements rather than using fixed high thresholds. The control unit continuously analyzes the output signals from the lifting force measuring device to identify load changes proportional to the actual payload, enabling precise measurement of small payloads while maintaining detection reliability through adaptive thresholding.
Solution Approach 2:
The system changes the detection parameter from fixed high thresholds to dynamic thresholding based on actual lifting force measurements. By analyzing the magnitude and rate of change of lifting force signals, the system adapts its detection sensitivity to match the actual payload size, ensuring both small and large payloads are measured with appropriate precision.
3Measurement precision
If manual taring of the weight of the load handling device is performed, then the system can operate with simple hardware, but the measurement precision deteriorates due to frequent errors when changing the load handling device
Solution Approach 1:
The system automatically determines the weight of the load handling device by analyzing the output signals from the lifting force measuring device during operation. The control unit monitors lifting force changes to identify when the load handling device weight is being measured, eliminating the need for manual taring operations and ensuring consistent, error-free weight measurements even when the load handling device changes.
Solution Approach 2:
The system replaces the mechanical/manual taring process with an automated electronic measurement system. Instead of requiring manual weighing operations, the control unit electronically determines the load handling device weight by analyzing lifting force signals, providing more precise and reliable measurements without manual intervention.
4Productivity
If the trigger threshold or rotation angle is not set correctly, then the system operates with simple hardware, but the productivity deteriorates due to no recording or falsified recording
Solution Approach 1:
The control unit autonomously manages the entire load cycle detection process without requiring manual threshold configuration. It automatically processes signals from both the lifting force measuring device and position detection system to accurately identify load cycle start and end points, ensuring complete and accurate recording of all load cycles regardless of payload size or handling device weight.
Solution Approach 2:
The system uses a universal detection approach that works across different load sizes, payload weights, and load handling device configurations. The control unit applies consistent automated analysis to all measurement scenarios, ensuring accurate load cycle recording whether the payload is small or large, and eliminating the need for different threshold settings for different operating conditions.
Data Source
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Figure 3a~3b
AI summary
The present invention relates to a system for the automatic detection of load cycles of a machine for handling loads, wherein the machine comprises a lifting device for lifting the load and a transport device for moving the load horizontally, with: a load change detection for automatically detecting a load change at least on the basis of the output signals of a lifting force measuring device, a load position detection which detects the position of the load in at least one horizontal direction, and a load cycle detection for automatically detecting a load cycle, wherein the load cycle detection is based at least on the output signals of the load change detection and the load position detection.According to the invention, the load cycle detection system stores the position of the load as the load point when a positive load change is detected and evaluates the positive load change as the beginning of a new load cycle based on a query as to whether the load has been moved a predetermined distance to the load point in the horizontal plane.