Reel Weight Measurement System for Load Compliance
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Solution Overview
Problem
Utility workers lack a reliable method to determine the weight of reels on reel-carrying units, leading to potential damage from exceeding load limits and non-compliance with DOT weight regulations, as they cannot accurately measure the weight of extracted cables and reels during transportation.
Innovation Solution
A weight measurement system for reel-carrying units equipped with sensors to measure orientation and forces, which, when processed by a processor, determine the weight of the reel, alerting users if limits are exceeded and allowing for tracking and reporting of reel weights for fleet management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If weight measurement sensors and processing systems are added to the reel-carrying unit, then weight determination accuracy is improved, but device complexity increases
Solution Approach 1:
The weight measurement system is segmented into distinct functional modules: sensors mounted on the reel-carrying unit to detect weight, processors to calculate weight from sensor data, and communication systems to transmit weight information. This segmentation allows each component to be optimized independently and simplifies the overall system architecture.
Solution Approach 2:
The reel-carrying unit's existing hydraulic lift system is made multi-functional by integrating weight measurement capabilities into it. The same hydraulic components that lift and position reels also serve as the measurement mechanism, eliminating the need for separate dedicated weighing infrastructure and reducing overall system complexity.
2Reliability
If real-time weight monitoring is implemented, then compliance with load limits and DOT regulations is improved, but loss of time in data processing and communication occurs
Solution Approach 1:
Weight data is collected and processed in advance during reel loading operations. The system continuously monitors weight as reels are loaded onto the carrier, so that by the time transportation begins, compliance status is already determined and documented, eliminating delays during actual transport operations.
Solution Approach 2:
The system implements continuous feedback loops where weight sensor data is immediately processed and compared against load limits and DOT regulations. This real-time feedback provides instant compliance verification, allowing operators to make immediate adjustments if needed, thereby ensuring reliable regulation compliance without significant time loss.
3Measurement precision
If multiple sensors and processing components are installed on the reel-carrying unit, then measurement capability is improved, but the weight of the reel-carrying unit increases
Solution Approach 1:
The reel-carrying unit's existing hydraulic system serves dual purposes: it performs the mechanical function of lifting and positioning reels while simultaneously providing the measurement function through its pressure sensors. This self-service approach means the system uses its own existing components for measurement rather than adding separate dedicated weighing equipment, minimizing additional weight.
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
Enables accurate weight determination of reels and cables, preventing damage and ensuring compliance with load and DOT regulations, while facilitating efficient fleet management by tracking and reporting reel weights.
Implementation Method 1
at least one first sensor disposed on the carriage and configured to measure at least one angle, wherein the at least one angle is indicative of the orientation of the carriage
Implementation Method 2
at least one second sensor disposed on the carriage and configured to measure at least one force on the carriage, wherein the at least one force is indicative of the weight of the reel
Implementation Method 3
determining the weight of the reel based at least in part on the at least one first signal and the at least one second signal
Data Source
AI summary
A reel weight measurement system is shown and described herein. In some embodiments, the reel weight measurement system comprises strategically placed position and load sensors for measuring an orientation of a reel-carrying unit and measuring loads in the reel-carrying unit. The loads may be indicative of forces due to the weight of the reel when the reel is supported by a carriage of the reel-carrying unit. The weight of the reel may be determined by summing the forces and moments in the system while the carriage is in motion or static. Further, the weight of the reel may be determined by comparing the force measurements and orientation of the carriage to stored calibration data.