On-board ULD Weight Estimation via Force and Acceleration
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Solution Overview
Problem
Existing cargo handling systems face inefficiencies and bottlenecks due to the lack of accurate weight estimation of unit load devices (ULDs) during transportation, as conventional weighing methods are time-consuming and impractical, leading to potential unbalanced loads and flight performance issues.
Innovation Solution
A system and method that estimates the mass of ULDs on-board a vessel using power drive units and sensors, applying forces and measuring accelerations to perform regression analysis and calculate the mass without physical weighing, allowing for real-time mass estimation and load balancing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional weighing methods are used to determine ULD weight, then measurement precision is improved, but productivity deteriorates due to time-consuming processes and bottlenecks
Solution Approach 1:
The patent replaces conventional mechanical weighing systems with a dynamic measurement system that uses force application and acceleration sensing. Power drive units apply known forces to ULDs, and sensors measure the resulting accelerations. The weight is calculated using Newton's second law (F=ma) through regression analysis, eliminating the need for physical scales and manual weighing procedures.
Solution Approach 2:
The system introduces power drive units and sensors as intermediary components between the ULD and the measurement process. These intermediaries enable indirect weight measurement by measuring the relationship between applied force and resulting acceleration, rather than directly measuring weight through conventional scales.
2Measurement precision
If conventional weighing methods are used, then measurement precision is improved, but loss of time worsens due to bottlenecks and slowdowns
Solution Approach 1:
The system enables continuous weight measurement as ULDs move through the cargo handling process. The power drive units and sensors operate continuously during ULD transport, allowing weight determination to occur during normal handling operations rather than requiring separate, time-consuming weighing steps.
Solution Approach 2:
The system performs weight measurement during the initial transport and positioning of ULDs on the conveyance surface, before final loading operations. This preliminary measurement eliminates the need for subsequent weighing steps and allows for early detection of weight issues.
3Productivity
If real-time mass estimation is implemented, then productivity is improved, but device complexity worsens due to additional sensors and control systems
Solution Approach 1:
The power drive units serve multiple functions: they transport ULDs along the conveyance surface and simultaneously act as force application devices for weight measurement. The sensors serve dual purposes by monitoring both ULD position/movement and acceleration data needed for weight calculation. This multi-functionality reduces the need for separate dedicated measurement equipment.
Solution Approach 2:
The system uses the existing infrastructure of power drive units and conveyance rollers to perform weight measurement. Rather than requiring entirely separate measurement equipment, the system leverages the operational components already present in the cargo handling facility, allowing them to serve both their primary transport function and the secondary measurement function.
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 and efficient mass estimation of ULDs, preventing unbalanced loads, optimizing flight operations, and reducing bottlenecks in cargo handling processes by calculating mass in real-time without the need for conventional scales.
Implementation Method 1
the at least one power drive unit configured to apply a first force to the unit load device and transmit a first force parameter in proportion to the first force to a system integrator, and the at least one power drive unit configured to apply a second force to the unit load device and transmit a second force parameter in proportion to the second force to the system integrator; at least one sensor configured to measure a first acceleration of the unit load device in response to the unit load device moving into a sensing zone disposed about the conveyance surface of the vessel as a result of the first force and transmit a first acceleration parameter in proportion to the first acceleration to the system integrator, the at least one sensor further configured to measure a second acceleration of the unit load device in response to the unit load device moving into the sensing zone disposed about the conveyance surface of the vessel as a result of the second force and transmit a second acceleration parameter in proportion to the second acceleration to the system integrator; wherein the system integrator is configured to calculate the mass of the unit load device while the unit load device is on-board the vessel by performing regression analysis on ordered pairs including the first force parameter and the first acceleration parameter, and the second force parameter and the second acceleration parameter
Data Source
AI summary
A system for estimating mass of a ULD while on-board a vessel includes a system controller energizing one or more PDUs in communication with a conveyance surface of the vessel, the PDUs applying first and second forces to the ULD and transmitting first and second force parameters to a system integrator, one or more sensors measuring first and second accelerations of the ULD when the ULD moves into one or more sensing zones as a result of the forces and transmits first and second acceleration parameters to the system integrator, and the system integrator, which receives the first and second force parameters, and the first and second acceleration parameters, and calculates the mass of the ULD while the ULD is on-board the vessel by performing regression analysis on ordered pairs including the first force parameter and the first acceleration parameter, and the second force parameter and the second acceleration parameter.