Pulley Block Rope Reeving Detection via Mechanical Measurement
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Solution Overview
Problem
Existing methods for automatically detecting the number of rope reevings in pulley blocks are susceptible to environmental influences like dirt, snow, and fog, and require costly camera systems for image recognition, which is not robust and economically viable.
Innovation Solution
A method that detects the rope path of at least one rope line and the height difference between the top and bottom blocks during a defined time window, using existing measurement systems to calculate the number of reevings by comparing the rope paths and height differences, which is more robust to external influences and reduces costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If optical/image-based detection methods are used to automatically detect the number of reevings, then automation is improved, but reliability deteriorates due to susceptibility to environmental influences like dirt, snow, and fog
Solution Approach 1:
The patent replaces optical/image-based detection with a mechanical measurement system. Rope path measurement devices (such as encoders or magnetic sensors) are integrated into the rope pulleys to directly measure the rope path length mechanically, eliminating susceptibility to environmental factors like dirt, snow, and fog that affect optical methods.
Solution Approach 2:
The patent introduces an intermediary measurement system that indirectly determines the number of reevings by measuring the rope path length. Instead of directly imaging the rope lines, the system uses rope path measurement devices to measure the length of rope that has been paid out or taken in, which can then be used to calculate the number of reevings based on the known relationship between rope path and reeving configuration.
2Extent of automation
If camera systems with image processing are installed for automatic detection, then automation is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex optical systems (cameras, lighting, image processing units) with simpler mechanical measurement devices. Rope path measurement devices such as encoders integrated into the rope pulleys or magnetic sensors provide direct mechanical measurement of rope displacement, eliminating the need for complex image capture and processing infrastructure.
Solution Approach 2:
The measurement system utilizes existing components in the pulley block system (the rope pulleys themselves) to perform the measurement function. By integrating encoders or magnetic sensors directly into the existing rope pulleys, the system leverages the mechanical structure already present, eliminating the need for separate camera systems and reducing overall device complexity.
3Extent of automation
If camera systems with image processing are installed for automatic detection, then automation is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive optical systems with cost-effective mechanical measurement devices. Rope path measurement devices such as encoders or magnetic sensors are significantly cheaper than camera systems with image processing capabilities, while providing more reliable measurements in harsh environmental conditions.
Solution Approach 2:
The system uses existing mechanical components (rope pulleys) to perform the measurement function, eliminating the need for expensive additional equipment. By integrating measurement devices into the existing pulley structure, the patent avoids the high costs associated with installing and maintaining separate camera systems.
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 method provides accurate and cost-effective detection of rope reevings, reducing susceptibility to environmental factors and simplifying retrofitting of existing systems by utilizing existing measurement technologies, ensuring reliable operation in crane technology.
Implementation Method 1
a rope path measurement device (160) for detecting a rope path of at least one rope line of the pulley block
Implementation Method 2
a height difference measurement device (60) for detecting a change of a height difference between the hook block and the trolley head
Data Source
AI summary
The disclosure relates to a method for determining the number of rope reevings of a pulley block with a top block and a bottom block, wherein the rope path of at least one rope line of the pulley block, which is covered during a time window, is detected and compared with at least one rope path of a further rope line covered within the time window and/or with the height difference between top block and bottom block changed within the time window, in order to determine the number of rope reevings of the pulley block.