Spreader Laser Scanner for Container Positioning Accuracy

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Container handling operations face challenges due to vibrations and shocks during crane operations, leading to precision issues and inefficiencies, especially in automated systems where sensor accuracy and calibration are critical but labor-intensive and prone to errors.

Innovation Solution

A method and apparatus using a distance sensor, such as a laser scanner, installed on a spreader to measure distances and determine reference lines matching the shape of interconnected cargo sides, mitigating measurement errors from vibrations and shocks, and allowing for improved positioning and handling accuracy without complex calibration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If sensors are installed to high altitudes (e.g., trolley structures 20 meters above ground) for automated crane operations, then the coverage area increases, but the positioning accuracy deteriorates due to amplified errors from sensor positioning errors and vibrations

Engineering Contradiction:

Improvecoverage areaVSAvoidpositioning accuracy

Core Design Contradiction:

Area of stationary objectVSMeasurement precision

Solution Approach 1:

The patent transitions from high-altitude 2D positioning to low-altitude 3D scanning. The laser scanner is mounted on the spreader at low altitude (near ground level) and scans vertically upward along the container stack, changing the measurement dimension from horizontal plane to vertical axis. This dimensional change eliminates the amplification of positioning errors that occurs at high altitudes.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent introduces an intermediary reference system - the container corners themselves serve as reference points. Instead of using a distant fixed reference frame that amplifies errors, the system uses the container's own geometric features (corners) as local references, measured by the laser scanner positioned close to them on the spreader.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Quantity of substance

If heavy containers are handled by the spreader, then the cargo handling capability increases, but the spreader bends under the weight, making dimension measurement difficult

Engineering Contradiction:

Improvecargo handling capabilityVSAvoiddimension measurement accuracy

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent replaces mechanical dimension measurement systems (physical rulers, calipers, or contact-based sensors) with an optical measurement system. The laser scanner uses light to measure distances and determine container dimensions without physically contacting or supporting the container, thereby eliminating measurement interference from spreader bending.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Extent of automation

If the spreader is positioned using the head block position in automated operations, then the automation capability increases, but the clearance between spreader and head block introduces positioning inaccuracy

Engineering Contradiction:

Improveautomation capabilityVSAvoidpositioning accuracy

Core Design Contradiction:

Extent of automationVSMeasurement precision

Solution Approach 1:

The system uses the laser scanner mounted on the spreader itself to measure container dimensions and position directly from the spreader's reference points. This self-measurement approach eliminates dependency on head block position measurements and the clearance issues between spreader and head block that cause positioning inaccuracies.

Inventive Principle:

Principle #25Self-service

4Reliability

If damping is applied to reduce vibrations and shocks during container handling, then the measurement stability improves, but the operation speed decreases due to increased delay

Engineering Contradiction:

Improvemeasurement stabilityVSAvoidoperation speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces mechanical damping systems (which physically absorb vibration energy and cause delays) with an optical measurement system. The laser scanner measures container dimensions and position in real-time during motion, using light travel time rather than mechanical measurement, thereby achieving vibration-resistant measurements without operational delays.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enhances the accuracy and efficiency of cargo handling by compensating for sensor movement and vibrations, reducing downtime, and simplifying the calibration process, thereby improving the precision and speed of container handling operations.

Implementation Method 1

measuring distances by reflected optical signals transmitted in the selected directions

Methodology Applied

Scientific EffectOptical reflection: Reflection

Data Source

PatentUS10414636B2Cargo handling by a spreader

Publication Date: 2019.09.17 KONECRANES GLOBAL OY

AI summary

There is provided improved accuracy in cargo handling by a spreader (306) including a distance sensor (308a, 308b) transmitting optical signals. The handled cargo (312) includes a plurality of interconnected sides (312a, 312b). The transmission directions of the optical signals are selected and distances are measured by reflected optical signals transmitted in the selected directions. The measured distances are used to determine a reference line that matches a shape of at least one of the interconnected sides (312a, 312b) of the cargo (312).