Pipelayer Lifting Capacity Determination Using Sensor Fusion
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Solution Overview
Problem
Operators of machines like pipelayers face challenges in accurately determining the lifting capacity, leading to increased risks of overturning or damage due to load imbalance and operator-dependent efforts, which affect machine performance.
Innovation Solution
A system comprising load, angle, and counterweight position sensors, along with a controller, that generates signals indicative of the load, angular position, and counterweight position to determine the lifting capacity of a pipelayer, providing real-time data to the operator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the operator visually determines the position of the counterweight system and estimates lifting capacity based on operational judgement, then the machine structure remains simple, but the measurement precision and reliability of lifting capacity determination deteriorates
Solution Approach 1:
The patent replaces the manual visual estimation method with an automated sensor-based measurement system. Load sensors, angle sensors, and counterweight position sensors automatically measure physical quantities and transmit data to a controller, eliminating the need for operator visual judgment and significantly improving measurement precision while maintaining acceptable system complexity
Solution Approach 2:
The patent introduces a controller as an intermediary that receives data from multiple sensors, processes the information, and calculates the lifting capacity. This intermediary component coordinates the various sensors and provides accurate real-time lifting capacity determination without requiring complex direct mechanical linkages between all components
2Device complexity
If the operator visually determines counterweight position and estimates lifting capacity, then the device complexity remains low, but the reliability of the lifting operation deteriorates due to possibility of overturning or damage
Solution Approach 1:
The patent implements a feedback system where sensors continuously monitor load, counterweight position, and boom angle, and the controller processes this information to provide real-time lifting capacity determination. This feedback loop enables the operator to make informed decisions about safe lifting operations, significantly improving reliability by preventing overload conditions that could cause overturning or damage
Solution Approach 2:
The patent replaces unreliable manual visual estimation with automated electronic sensing and calculation systems. The load sensor, angle sensor, and counterweight position sensor provide objective, precise measurements that are processed by the controller to determine actual lifting capacity, eliminating human error and improving operational safety
3Measurement precision
If multiple sensors and a controller are added to determine lifting capacity accurately, then the measurement precision and reliability improve, but the device complexity increases
Solution Approach 1:
The patent designs the controller to perform multiple functions: receiving data from various sensors, calculating lifting capacity, and potentially controlling boom and counterweight movements. By making the controller a multi-functional component, the system achieves high measurement precision without proportionally increasing overall system complexity, as one component handles multiple tasks
Data Source
AI summary
A system for determining a lifting capacity of a pipelayer is provided. The system includes a load sensor configured to generate a signal indicative of a load suspended from a lifting hook, an angle sensor configured to generate a signal indicative of an angular position of a chassis relative to ground surface, a boom position sensor configured to generate a signal indicative of a position of a boom relative to an undercarriage, and a counterweight position sensor configured to generate a signal indicative of a position of a counterweight relative to the undercarriage. The system further includes a controller configured to receive the signal from each of the load sensor, the angle sensor, the boom position sensor, and the counterweight position sensor. The controller is also configured to determine the lifting capacity of the pipelayer based, at least in part, on the received signal.