Magnetic Rope Winding System for Crane Tension Control

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Solution Overview

Problem

Existing rope winding systems for cranes face issues with uneven loading and wear on steel ropes due to mechanical contact, leading to skipping and damage, and previous solutions are either complex or ineffective in maintaining tension without mechanical contact.

Innovation Solution

A rope winding system that uses a magnetic system to generate a braking force on the steel rope through a magnetic field, minimizing mechanical contact and wear, and includes a load detecting means for optimal tension control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If pressure rollers are used to apply constant load to the steel rope, then the rope can be uniformly wound onto the rope drum, but the pressure rollers cause high wear and tear of the steel rope and may skip leading to damage

Engineering Contradiction:

Improveuniform winding of steel ropeVSAvoidwear and tear of steel rope

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical pressure roller system with a magnetic field-based loading system. Magnets are arranged in a circle around the rope drum, creating a magnetic field that applies constant radial pressure to the steel rope without mechanical contact. This substitution eliminates the wear and tear caused by pressure rollers while maintaining uniform winding through consistent magnetic loading.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If pressure rollers are used to maintain tension on the steel rope, then winding uniformity is improved, but the complexity of the system increases and maintenance requirements increase

Engineering Contradiction:

Improvewinding uniformityVSAvoidcomplexity of rope winding system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The mechanical pressure roller system is replaced with a magnetic field generation system consisting of magnets arranged in a circle. This substitution simplifies the system by eliminating mechanical contact components while maintaining the tension application function. The magnetic field provides consistent radial pressure without requiring mechanical adjustment mechanisms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If outer and inner rope drums are provided to store unused rope length, then the rope can be loosely wound without loading, but the system becomes very complex and no load is built up on the rope

Engineering Contradiction:

Improveloose winding of ropeVSAvoidcomplexity of rope drum arrangement

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent extracts the rope storage function from the winding system by using a separate reel for storing unused rope length. This allows the main rope drum to focus solely on the winding operation with proper tension application, while the separate reel handles the storage function. This separation reduces the complexity of integrated systems like the outer and inner rope drums.

Inventive Principle:

Principle #2Taking out (Extraction)

4Force

If mechanical contact is used to apply load to the steel rope, then tension can be maintained during winding, but wear and tear occurs and the rope lifespan is reduced

Engineering Contradiction:

Improvetension on steel ropeVSAvoidlifespan of steel rope

Core Design Contradiction:

ForceVSDuration of action of stationary object

Solution Approach 1:

The patent replaces mechanical contact-based tension application with a magnetic field-based system. Magnets arranged in a circle around the rope drum create a magnetic field that applies radial pressure to the steel rope, maintaining tension without mechanical contact. This eliminates wear and tear at the contact points, significantly extending the rope's operational lifespan.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 magnetic system ensures uniform winding and reduced wear on the steel rope by maintaining tension without mechanical contact, improving the winding process and extending the lifespan of the rope.

Implementation Method 1

a magnetic system (3) which is arranged in such a way that a magnetic field can be generated with its magnetic flux being deflected by a movement of the steel rope (4) in such a way that the steel rope (4) is braked

Methodology Applied

Scientific EffectMagnetic field interaction: Magnetic Field

Implementation Method 2

The magnetic system (3) ensures uniform winding and reduced wear on the steel rope (4) by maintaining tension without mechanical contact

Methodology Applied

Scientific EffectEddy current braking: Eddy Current Damping

Data Source

PatentUS7770744B2Rope winding system for winding and unwinding steel ropes of cranes

Publication Date: 2010.08.10 TADANO DEMAG GMBH

AI summary

The present invention relates to a rope winding system (1) for winding and unwinding a steel rope (4) of a crane (7). A rope winding system (1) according to the present invention has a rope drum (6), onto which the steel rope (4) can be wound in a plurality of layers, and a magnetic system (7) which is configured to generate a magnetic field over a section of the steel rope (4) with its magnetic flux being deflected by a movement of the steel rope (4) in such a way that the steel rope (4) is braked. A crane (7) is also discloses which is equipped with such a rope winding system (1) for winding and unwinding a steel rope (4).