Wireless Crane Control Switch with Near-Field Hand Detection

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Solution Overview

Problem

Existing control switches for machines like cranes rely on dead-man's buttons that require continuous activation, which can lead to inadvertent interruptions and are not ergonomic, as they depend on the operator actively holding a button rather than simply being present.

Innovation Solution

A wireless, portable control switch with a safety circuit that uses multiple near-field sensors to detect the operator's hand in the gripping region, eliminating the need for dead-man's buttons by continuously monitoring hand presence and allowing operation as long as the operator holds the switch, with sensors arranged orthogonally to ensure activation by one hand only.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If dead-man's buttons are used for continuous activation, then safety is improved, but ergonomics deteriorate and inadvertent interruptions occur

Engineering Contradiction:

ImprovesafetyVSAvoidergonomics

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces the mechanical dead-man's button system with an optical sensor system. The sensor detects the operator's presence through optical means (light reflection from the hand), eliminating the need for continuous mechanical button pressure. This substitution maintains safety through automated detection while dramatically improving ergonomics by allowing natural hand positioning on the control device.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an intermediary optical sensor system between the operator and the control function. Instead of direct mechanical contact (button), the sensor acts as an intermediary that detects the operator's hand presence and automatically activates/deactivates control functions. This intermediary layer prevents inadvertent interruptions while maintaining continuous safety monitoring.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If dead-man's buttons require active holding, then control activation is ensured, but operation is restricted and interruptions occur

Engineering Contradiction:

Improvecontrol activationVSAvoidoperation flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent inverts the traditional control logic: instead of requiring active button holding to maintain activation, the system activates control functions by detecting the absence of the hand (when the hand is removed, control is deactivated). This inversion eliminates the need for continuous active holding while ensuring control activation only when the operator is present, thereby improving both reliability and operational flexibility.

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of operation

If sensors are added to detect hand presence, then dead-man's buttons can be eliminated, but device complexity increases

Engineering Contradiction:

ImproveergonomicsVSAvoidsensor system

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent integrates the optical sensor system into the existing control device housing, making the sensor serve multiple functions: detecting hand presence, determining control activation state, and potentially monitoring operational parameters. This multi-functionality approach eliminates the need for separate dead-man's buttons while adding minimal complexity, as the sensor system replaces rather than supplements existing control mechanisms.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 ergonomics and safety by ensuring the control switch remains active only when the operator is present and holding it, reducing the risk of unintended operation and allowing both right- and left-handed use without restricting the operation's functionality.

Implementation Method 1

the detecting device comprises at least one sensor which detects in a near field an operator's hand holding the control switch in the gripping region

Methodology Applied

Scientific EffectNear-field detection: Electromagnetic Induction

Data Source

PatentUS9776839B2Control station for operating a machine, in particular a wireless, portable, and manually operated remote control for a crane

Publication Date: 2017.10.03 KONECRANES GLOBAL OY

AI summary

A control switch for operating a machine, the control switch including a housing that includes a gripping region for an operator, and a detecting device for detecting an operator. The control switch further includes a safety circuit for activating the control switch when an operator is detected, and deactivating the control switch when the operator is not detected. The safety circuit includes a detecting device that includes at least one sensor operable to detect in a near field an operator's hand holding the control switch in the gripping region. The detecting device includes at least one additional sensor which detects a use of the control switch.