Spreader Beam Fault Detection via Load and Inclination Monitoring
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Solution Overview
Problem
Crane systems with spreader beams face complex fault detection challenges due to variables such as hoist snagging, incorrect attachment, and imbalance, which existing technologies fail to accurately diagnose automatically, posing risks to equipment and personnel.
Innovation Solution
A method that monitors loadings at each load point and the inclination of the spreader beam relative to a horizontal plane, comparing these against defined thresholds to detect fault conditions, allowing for dynamic adjustment of thresholds and ranges to prevent false alarms and adapt to changing conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If multiple hoists are used with a spreader beam to distribute loading, then the loading at each attachment point is reduced, but the complexity of fault detection and diagnosis increases significantly
Solution Approach 1:
The system divides the monitoring function into separate sensors for each hoist and load point, allowing individual monitoring of each component. This segmentation enables precise identification of which specific hoist or load point is experiencing a fault condition, transforming a complex system-wide problem into manageable individual measurements that can be analyzed separately and then integrated for comprehensive diagnosis.
2Reliability
If automated or remote operation is implemented, then operator safety is improved, but the ability to detect and respond to fault conditions is reduced
Solution Approach 1:
The system implements continuous feedback by monitoring loadings at each load point and comparing them against expected values. When deviations indicate fault conditions such as snagging or incorrect attachment, the system automatically generates alerts and can trigger corrective actions. This closed-loop feedback mechanism compensates for the absence of human operators, providing automated detection and response to maintain both safety and operational awareness.
3Measurement precision
If continuous monitoring of all load points is implemented, then fault detection accuracy is improved, but the device complexity and cost increase
Solution Approach 1:
The system applies monitoring selectively at critical locations - specifically at each load point where hoists attach to the spreader beam. Rather than implementing universal monitoring throughout the entire crane system, the solution focuses measurement resources on the specific points where fault conditions are most likely to occur and can be most effectively detected, optimizing the balance between detection accuracy and system complexity.
Data Source
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AI summary
A method of detecting a fault condition in a crane system (10), the crane system comprising a spreader beam (40) for lifting a load, the spreader beam comprising at least two load points (52), each load point being arranged to support a respective portion of the load, wherein the method comprises: monitoring respective loadings applied to each of the load points; analysing the loadings to determine whether the crane system is operating outside of one or more acceptable load ranges; monitoring an inclination of the spreader beam relative to a horizontal plane; comparing the inclination with an inclination threshold to determine whether the crane system is operating outside of the inclination threshold; and determining the existence of a fault condition if the crane system is operating outside of the inclination threshold or at least one of the acceptable load ranges.