Zero-Gravity Hoist Force Sensing for Precise Load Positioning
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Solution Overview
Problem
Existing hoist systems lack precision control when lifting or maneuvering large and heavy loads, often relying on push button controllers that do not allow for fine adjustments.
Innovation Solution
A zero-gravity hoist system with a chain fall, motor, power supply, and controller equipped with electronic processors that measure and adjust load forces to achieve precise height control, using a load sensing assembly with spring plates and sensors to detect force changes and adjust accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If push button controllers are used for hoist control, then the device complexity is reduced, but the manufacturing precision and control precision deteriorate
Solution Approach 1:
The patent replaces traditional mechanical push button controllers with an electronic control system that uses load sensors to detect force changes and automatically adjusts motor output. This substitution enables precise load position control through electronic feedback mechanisms while maintaining relatively simple device architecture.
Solution Approach 2:
The system implements feedback control by using load sensors to continuously monitor force applied to the load, comparing it with target values, and automatically adjusting motor commands to achieve precise position control. This closed-loop feedback mechanism enables high manufacturing precision without requiring complex manual control interfaces.
2Manufacturing precision
If force sensing and automatic adjustment mechanisms are added, then the manufacturing precision improves, but the device complexity increases
Solution Approach 1:
The controller is designed to perform multiple functions: it processes load sensor signals, determines force changes, generates motor control commands, and manages system state. This multi-functionality consolidates what could be separate complex components into a single integrated unit, improving precision while limiting the increase in overall system complexity.
Solution Approach 2:
The system automatically detects force changes through load sensors and self-adjusts motor output without requiring complex external control mechanisms. This self-service capability allows the system to achieve high precision control through automatic feedback loops rather than requiring additional complex control hardware or manual intervention.
3Measurement precision
If load sensing assembly with spring plates and sensors is used, then the measurement precision improves, but the device complexity increases
Solution Approach 1:
The spring plate acts as an intermediary mechanical element that converts complex three-dimensional load forces into uniaxial deflection movements. This intermediary component simplifies the measurement task for the sensor while maintaining high measurement precision, as the sensor only needs to detect linear displacement of the spring plate rather than complex force vectors.
Solution Approach 2:
The patent replaces complex mechanical force measurement mechanisms with an electronic sensor system that detects spring plate deflection. This substitution uses electrical signals to measure force, providing high measurement precision while reducing mechanical complexity compared to traditional mechanical force sensors or load cells.
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 fine manipulations of loads with minimal user effort by requiring affirmative force application, reducing oscillations and accidental inputs, and allowing for precise height adjustments based on force differences.
Implementation Method 1
a first sensor configured to apply a first electrical signal to a first conductive surface associated with the spring plate. The first sensor includes a first antenna configured to receive a signal from the first conductive surface, wherein the first electrical signal is dependent on a distance between the first antenna and the first conductive surface
Implementation Method 2
The load sensing assembly includes a spring plate configured to deflect in a first direction when the force of the load increases
Data Source
AI summary
A zero-gravity hoist system including a chain fall, a motor coupled to the chain fall and configured to drive the chain fall in one or more directions, a power supply configured to provide power to the motor, and a controller having one or more electronic processors. The one or more electronic processors are configured to measure a first force of a load in response to receiving an input, store the measured first force in a memory of the controller, measure a second force of the load, determine a difference between the second measured force and the first measured force, and adjust a height of the load based on determining that the second force differs from the first force by a predetermined threshold.