Remote Power Lock System for Stage Truss Towers
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Solution Overview
Problem
Current stage truss systems require manual labor to lock truss towers, which is time-consuming and risky, especially in adverse weather conditions, as they lack a reliable mechanism to transfer loads efficiently and securely without personnel climbing the towers.
Innovation Solution
A remotely operated locking system for truss towers, equipped with adjustable locking mechanisms and sensors, allows for precise alignment and operation of locking forks to securely engage and disengage the load, eliminating the need for stagehands to climb towers and enhancing safety during wind and seismic events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual locking methods are used for truss towers, then personnel can directly engage locking mechanisms, but it requires stagehands to climb towers which is time-consuming and risky especially in adverse weather conditions
Solution Approach 1:
The patent replaces manual mechanical locking operations with an automated power lock system. The system uses electric motors to drive locking forks that automatically engage with stirrup receptacles on the sleeve block, eliminating the need for personnel to manually climb and lock towers. This substitution of manual mechanical operations with automated mechanical systems directly resolves the contradiction by improving safety while reducing setup time.
Solution Approach 2:
The power lock system enables the truss tower structure to lock itself automatically. The control system coordinates the operation of multiple locking mechanisms across different towers without requiring human intervention at each location. The system self-manages the locking process through automated fork extension and engagement with the sleeve block receptacles, resolving the time and safety issues associated with manual operation.
2Productivity
If remote power lock system is implemented, then setup time is reduced and safety is improved, but the device complexity increases with additional mechanisms and control systems
Solution Approach 1:
The power lock system is divided into modular components: individual locking mechanisms for each tower, separate control systems for each locking mechanism, and standardized stirrup receptacles on the sleeve block. Each tower's locking system operates independently but is coordinated through the control system. This segmentation allows the complex function to be achieved through multiple simple, standardized modules rather than one complex integrated system.
Solution Approach 2:
The locking fork design and stirrup receptacle configuration are made universal across all towers in the system. The same basic locking mechanism and engagement interface are used on every tower, allowing standardized components to perform multiple locking functions. This universality reduces overall system complexity by repeating proven simple designs rather than creating unique complex solutions for each tower.
3Reliability
If locking forks are extended into stirrup receptacles, then load transfer to tower is secured, but the mechanism requires precise alignment which complicates the locking process
Solution Approach 1:
The control system incorporates feedback mechanisms to monitor the position and engagement status of locking forks with stirrup receptacles. Sensors detect when forks are properly aligned and engaged, providing real-time status information to the control system. This feedback ensures reliable load transfer by confirming proper engagement while simplifying operation through automated position verification and adjustment.
Solution Approach 2:
The system performs preliminary alignment actions before final locking engagement. The control system coordinates the movement of locking forks to pre-align with stirrup receptacles before extending them into the engagement position. This preliminary positioning action ensures that the subsequent locking engagement is straightforward and reliable, reducing the operational complexity of achieving precise alignment during the actual locking process.
Data Source
AI summary
A power lock system for stage truss towers for remotely locking a climbing truss sleeve block with its tower, thereby distributing the downward load directly into the tower and preventing upward motion. The power lock system for stage truss towers generally includes a remotely controlled locking mechanism that is mounted within a truss tower section with adjustable locations. The sleeve that slides or rolls up the tower is equipped with stirrups to provide a structural receptacle for the locking forks. The sleeve and the locking mechanism are equipped with sensors that indicate the sleeve is in the correct location for locking. The control system displays the status of the sensors and limit switches and uses logic to exercise the rules of operation.