Modular Counterweight Carriage for Large Cranes
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Solution Overview
Problem
Large cranes with counterweight systems face challenges in achieving high lifting capacities without requiring large, complex, and expensive counterweight carriages, especially when mobility and stability are compromised for small-to-medium loads.
Innovation Solution
A modular counterweight system is introduced, dividing the counterweight into traveling and non-traveling components, where the non-traveling counterweight is activated first, allowing the traveling counterweight to be activated only when necessary, using a crossbeam connected to both counterweights and equipped with chains or hydraulic cylinders for adjustable length, enabling the separation of the non-traveling counterweight from the crossbeam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large counterweight carriage is used to achieve high lifting capacity, then the lifting capacity is improved, but the device complexity and cost increase significantly
Solution Approach 1:
The counterweight is divided into multiple segments: a basic counterweight that travels with the crane and additional counterweight modules that can be added as needed. Each module consists of a counterweight block and a carriage, allowing the system to achieve high lifting capacity through modular addition rather than a single large complex structure.
2Quantity of substance
If a large counterweight carriage is used to achieve high lifting capacity, then the lifting capacity is improved, but the manufacturing cost increases
Solution Approach 1:
The counterweight system is segmented into standardized modules that can be manufactured independently and assembled on-site. This modular approach reduces manufacturing complexity and cost compared to building a single large custom carriage, while still achieving the required total counterweight mass for high lifting capacity.
3Adaptability or versatility
If the counterweight is divided into traveling and non-traveling components, then the mobility is improved, but the device complexity increases
Solution Approach 1:
The counterweight system transitions from a static single-mass design to a dynamic modular system where counterweight modules can be added or removed based on operational requirements. The traveling counterweight moves with the crane while non-traveling modules remain stationary, providing adaptability without requiring complex mechanisms for each module.
4Stability of the object's composition
If the non-traveling counterweight is activated first, then the stability is improved, but the activation sequence complexity increases
Solution Approach 1:
The non-traveling counterweight is positioned and activated in advance before the traveling counterweight is engaged. This preliminary placement of the stationary counterweight provides initial stability for the crane structure, while the traveling counterweight is then added to achieve the full lifting capacity without requiring complex coordinated activation sequences.
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
This design maximizes lifting capacity and mobility while minimizing additional investment costs, allowing cranes to maintain original operational capacity with reduced need for extensive counterweight carriage modifications and enabling efficient transportation of expansion parts.
Implementation Method 1
at least one hydraulic cylinder or reeved cable is provided between the non-traveling counterweight and the crossbeam
Data Source
AI summary
A large mobile crane includes a revolving superstructure, a main boom hinged to the superstructure, and a derrick boom hinged to the superstructure. A modular counterweight system includes a traveling counterweight and a non-traveling counterweight connected to a crossbeam suspended from the distal end of the derrick boom so that the non-traveling counterweight is activated before the traveling counterweight.