Pipelayer Load Drop Control Using Orientation-Based Thresholds
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Solution Overview
Problem
Pipelayers, especially those operated by unskilled or distracted operators, face overload conditions leading to unintended effects such as tipping, causing damage to the machine and other nearby pipelayers, as existing systems fail to address the operator's inability to adjust operations in time to prevent these issues when working in conjunction with other machines.
Innovation Solution
A controller system that monitors load and orientation data from multiple machines, determines a load drop condition based on thresholds, and performs actions such as alerting operators or automatically dropping loads to prevent tipping, while also transmitting information to other machines to adjust their operations accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If automated load drop system is implemented, then operator skill requirement is reduced and machine safety is improved, but device complexity increases
Solution Approach 1:
The system enables the machine to automatically monitor its own load conditions, detect potential tipping scenarios, and execute load drop actions without human intervention. The controller continuously receives data from sensors, processes stability information, and autonomously determines when to drop the load based on pre-programmed criteria, making the system self-monitoring and self-protecting.
Solution Approach 2:
The patent replaces the mechanical judgment and manual operation required by skilled operators with an electronic control system. Sensors, processors, and algorithms substitute for human sensory perception and decision-making, converting a manually-operated safety function into an automated electronic control system that continuously monitors and responds to load conditions.
2Speed
If automated load drop is performed, then response time to prevent tipping is reduced, but loss of control by operator increases
Solution Approach 1:
The system continuously receives feedback from sensors monitoring load weight, machine orientation, and stability parameters. This real-time feedback loop enables the controller to detect changing conditions and automatically adjust by dropping the load when instability is detected, providing continuous monitoring and automatic response without requiring operator attention or skill.
Solution Approach 2:
The controller is pre-programmed with stability criteria and drop conditions based on engineering analysis. When sensor data indicates approaching unsafe conditions, the system has already determined the appropriate response threshold and action, enabling immediate automatic load drop without requiring real-time operator judgment or delayed human response.
3Reliability
If load is dropped automatically, then damage to machine and pipeline segments is prevented, but coordination with other pipelayers becomes more complex
Solution Approach 1:
The controller acts as an intermediary between the physical load-bearing system and the automatic drop mechanism. It receives raw sensor data, processes stability information against pre-programmed criteria, and translates this into coordinated control signals that simultaneously manage the load drop timing and communicate with other pipelayers, simplifying the coordination complexity through centralized intelligent control.
Data Source
AI summary
A controller may obtain, from one or more first devices of a first machine, first information regarding a load associated with a first portion of an object. The first portion, of the object, may be carried by an implement of the first machine and a second portion, of the object, may be carried by an implement of a second machine. The controller may obtain, from one or more second devices of the first machine, second information regarding an orientation of the first machine. The controller may determine, based on the first information and a threshold derived based on the second information, that a load drop condition is satisfied; perform a first action associated with dropping the load; and transmit, to the second machine, information regarding the first action to cause the second machine to perform a second action.