Ruggedized Optical Sensor Packaging for Crane Stability Monitoring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing linear distance measurement systems in harsh environments, such as construction equipment, face challenges with mechanical wear, debris interference, and limited resolution, particularly in crane outrigger stability monitoring.
Innovation Solution
A ruggedized measurement system incorporating an optical distance sensor, a target, and a sealed outer sleeve with an inner member, which minimizes debris infiltration and maintains accuracy by using an enclosed cavity with inert gas or controlled venting to manage pressure and moisture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an optical measurement system is used, then measurement accuracy is improved, but susceptibility to dirt and airborne particulates worsens
Solution Approach 1:
A protective enclosure with transparent window acts as an intermediary barrier between the optical sensor and the harsh environment. The optical beam passes through the transparent window while dust and particulates are blocked, allowing the sensor to maintain high accuracy without direct exposure to contaminants
Solution Approach 2:
The patent replaces traditional mechanical measurement systems (string potentiometers, magnetic sensors) with an optical measurement system that uses light instead of mechanical contact. This eliminates mechanical wear and tear while maintaining measurement capability, though it introduces susceptibility to environmental factors that are then mitigated through protective design
2Reliability
If traditional physical sensors are used, then mechanical durability is improved, but measurement resolution worsens
Solution Approach 1:
The patent replaces mechanical sensing mechanisms with optical sensing that uses light reflection and time-of-flight measurements. This substitution provides both high measurement resolution (capable of detecting sub-millimeter changes) and improved reliability since there are no mechanical moving parts to wear or fail
3Ease of operation
If an open optical sensor is used, then ease of operation is improved, but susceptibility to debris infiltration worsens
Solution Approach 1:
A transparent protective window serves as an intermediary that allows the optical sensor to remain accessible and functional while blocking debris infiltration. The window is positioned to allow optical beam passage while preventing physical contact between contaminants and the sensor elements
Solution Approach 2:
The protective enclosure uses a transparent window (thin film structure) that is optically transparent yet physically protective. This thin barrier maintains sensor accessibility for alignment and operation while providing effective protection against dust and debris infiltration
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 system provides accurate, durable, and reliable linear distance measurement in harsh environments, reducing mechanical wear and interference from debris, thereby enhancing crane stability monitoring.
Implementation Method 1
an optical distance sensor measures a distance to a target
Implementation Method 2
there is a seal between the inner member and the outer sleeve
Implementation Method 3
a desiccant is disposed in the outer sleeve
Implementation Method 4
a check valve is disposed in the hole
Data Source
AI summary
A ruggedized packaging assembly for a linearly extending crane component measurement device includes an outer sleeve, an inner member slidably disposed in the outer sleeve, a target coupled to at least one of the outer sleeve and the inner sleeve, and a non-contact measurement instrument. Either the outer sleeve or the inner member is coupled to a linearly extending component, and the other part is coupled to a component from which a distance is being measured.