Pre-Crush Sensor Module for Aerial Lift Entrapment Prevention
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Solution Overview
Problem
Operators in aerial lifts can become trapped between the basket and obstacles before they can release the safety switch or activate the emergency stop, leading to potentially fatal entrapment events, as existing safety devices only react after the event occurs.
Innovation Solution
A pre-crush sensor module with a plurality of sensors that detect obstacles within a specific detection zone above and behind the operator, alerting them to potential hazards and preventing further movement of the basket or cage before a collision can happen, which can be integrated with existing safety devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing safety devices (footswitch or dead man's handle) are used to prevent basket movement, then operator safety is improved, but the response time is too slow as operators can become trapped before releasing the safety switch or activating emergency stop
Solution Approach 1:
The pre-crush sensor module performs preliminary detection of obstacles in the detection zone before they can reach the operator. The sensors continuously monitor the area in front of, above, and behind the operator, and trigger an alarm or prevent basket movement before entrapment can occur, rather than waiting for the operator to manually activate safety switches after detecting danger
Solution Approach 2:
The system implements continuous feedback through sensors that monitor the detection zone and provide real-time information about obstacle presence. When an obstacle is detected, the system immediately provides feedback through alarm signals and control system activation, creating a closed-loop safety mechanism that responds automatically without requiring operator intervention
2Reliability
If a detection zone is created around the operator to detect obstacles, then entrapment prevention is improved, but the device complexity increases due to multiple sensors and detection zones
Solution Approach 1:
The detection zone is segmented into multiple distinct sensor zones: a front detection zone in front of the operator, an upper detection zone above the operator, and a rear detection zone behind the operator. Each zone is monitored by dedicated sensors, allowing the system to provide specific directional warnings and respond appropriately to obstacles in different locations without requiring a single complex omnidirectional sensor system
Solution Approach 2:
The pre-crush sensor module is designed as a universal safety system that can be integrated with existing aerial lift control systems. The module provides multiple functions including obstacle detection, alarm signaling, and control system activation, making it a multi-functional unit that enhances safety without requiring complete system replacement
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
A pre-crush sensor module for use with a safety device for an aerial lift (10) having a basket or cage (20), the pre-crush sensor module having removably attachable sensors (36) which provide a detection zone (28) wherein the sensors detect obstacles. The sensor module also has an operator warning system (40) and a relay to connect the sensors to the safety device. The module comprises two upward facing sensors (36) mounted on a control panel of the aerial lift, two rearward facing sensors (30) mounted on a back of the basket or cage and four angled-rearward facing sensors (32) mounted on the back of the basket or cage.