The present invention relates to improved arrangements for rotational apparatus. In particular, embodiments of the present invention relate to improved arrangements for orientation control apparatus for larger loads and associated methods.
In industries such as, but not limited to transportation and construction, loads are suspended, moved and relocated multiple times before being placed in a final position. The movement of suspended loads, for example, via cranes, can pose a risk to surrounding workers and structures. While certain aspects of movement can be controlled by the crane, rotation of a load can often be unpredictable and influenced suddenly by environmental factors, such as wind and/or the nature of the load itself. It is known to control the rotation of the load by using one or more gyroscopes. Indeed, the Applicant has devised improved load management systems and methods for the tracking and control of loads which include control moment gyroscope (CMG) modules in which the orientation of the suspended load is controlled by transferring the angular momentum within the control moment gyroscopic modules. The Applicant's improved load management systems and methods are the subject of International patent application no. PCT/AU2016/050941 which is incorporated herein by reference in its entirety.
In addition, there are other known technologies utilising other physical principles to achieve rotational control, such as the use of fans and the movement of a liquid around an enclosed chamber. However, none of these technologies address the problems encountered with very heavy, long and/or wide loads. For example, whilst one of the features of the Applicant's existing devices is the ability to scale both the size and the number of individual gyroscopic modules, which gives the system considerable flexibility, there will be situations where space, weight and/or economic constraints require further functionality to achieve a viable solution.
Limitations of the existing systems arise with very heavy loads, and with very long or wide loads. One example of such a load is a wind power generation turbine blade. Wind turbine blades are very long in comparison to their mass, giving rise to very high rotational inertia compared to the mass, and the potential for very high unbalanced wind loads. In contrast, there are components of offshore structures, such as large vertical columns or pipes, which have a very high concentrated mass, so that friction in a swivel between a crane hook and a crane hoist rope becomes a significant factor in the total torque required to orient the load.
The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.
It is a preferred object of the present invention to provide an improved arrangement for rotational apparatus, and/or an improved method, and in particular, an improved orientation control apparatus that addresses or at least ameliorates one or more of the aforementioned problems of the prior art and/or provides a useful commercial alternative.
Generally, the present invention relates to improved arrangements for rotational apparatus, and in particular to orientation control apparatus for controlling the rotational orientation of larger loads suspended from the apparatus, and associated methods.
In one form, although not necessarily the broadest or only form, the invention resides in an orientation control apparatus for controlling rotational orientation of a load suspended from the apparatus, the apparatus comprising:
a housing or framework for coupling to the load;
at least one gyroscope or gyroscopic module mounted to the housing or framework;
one or more thrusters movably mounted directly or indirectly to the housing or framework via one or more mounting elements to vary a position of the one or more thrusters from a centre of the housing or framework; and
a controller in communication with the at least one gyroscope or gyroscopic module, the one or more thrusters and the one or more mounting elements to control a proportion of rotational force applied to the load from the at least one gyroscope or gyroscopic module and the one or more thrusters to control the rotational orientation of the load.
Suitably, the apparatus comprises a motorized frictionless swivel coupled directly or indirectly to the housing or framework and to one or more lines suspending the load and the controller is in communication with the motorized frictionless swivel to control a proportion of rotational force applied to the load from the motorized frictionless swivel.
According to another embodiment, although not necessarily the broadest embodiment, the invention resides in an orientation control apparatus for controlling rotational orientation of a load suspended from the apparatus, the apparatus comprising:
a housing or framework for coupling to the load;
at least one torque generating device mounted to the housing or framework;
a motorized frictionless swivel coupled directly or indirectly to the housing or framework and to one or more lines suspending the load; and
a controller in communication with the at least one torque generating device and the motorized frictionless swivel to control a proportion of rotational force applied to the load from the at least one torque generating device and the motorized frictionless swivel to control the rotational orientation of the load.
Suitably, the apparatus comprises one or more thrusters movably mounted directly or indirectly to the housing or framework via one or more mounting elements to vary a position of the one or more thrusters from a centre of the housing or framework and the controller is in communication with the one or more thrusters to control a proportion of rotational force applied to the load from the one or more thrusters.
According to another embodiment, although not necessarily the broadest embodiment, the invention resides in an orientation control apparatus for controlling rotational orientation of a load suspended from the apparatus, the apparatus comprising:
a housing or framework for coupling to the load;
a motorized frictionless swivel coupled directly or indirectly to the housing or framework and to one or more lines suspending the load;
one or more thrusters movably mounted directly or indirectly to the housing or framework via one or more mounting elements to vary a position of the one or more thrusters from a centre of the housing or framework; and
a controller in communication with the motorized frictionless swivel and the one or more thrusters to control a proportion of rotational force applied to the load from the motorized frictionless swivel and the one or more thrusters to control the rotational orientation of the load.
Suitably, the apparatus comprises at least one torque generating device mounted to the housing or framework and the controller is in communication with the at least one torque generating device to control a proportion of rotational force applied to the load from the at least one torque generating device.
In another form, although not necessarily the broadest form, the invention resides in a method of controlling rotational orientation of a load, the method comprising:
coupling a housing or framework to the load;
mounting at least one torque generating device to the housing or framework;
movably mounting one or more thrusters directly or indirectly to the housing or framework via one or more mounting elements to vary a position of the one or more thrusters from a centre of the housing or framework; and
controlling the rotational orientation of the load by controlling a proportion of rotational force applied to the load from the at least one torque generating device and the one or more thrusters via a controller in communication with the at least one torque generating device, the one or more thrusters and the one or more mounting elements.
Suitably, the method comprises coupling a motorized frictionless swivel directly or indirectly to the housing or framework and to one or more lines suspending the load and the controller, in communication with the motorized frictionless swivel, controlling a proportion of rotational force applied to the load from the motorized frictionless swivel.
According to another embodiment, the invention resides in a method of controlling rotational orientation of a load, the method comprising:
coupling a housing or framework to the load;
mounting at least one torque generating device to the housing or framework;
coupling a motorized frictionless swivel directly or indirectly to the housing or framework and to one or more lines suspending the load; and
controlling the rotational orientation of the load by controlling a proportion of rotational force applied to the load from the at least one torque generating device and the motorized frictionless swivel via a controller in communication with the at least one torque generating device and the motorized frictionless swivel.
Suitably, the method comprises movably mounting one or more thrusters directly or indirectly to the housing or framework via one or more mounting elements to vary a position of the one or more thrusters from a centre of the housing or framework and the controller, in communication with the one or more thrusters, controlling a proportion of rotational force applied to the load from the one or more thrusters.
According to another embodiment, the invention resides in a method of controlling rotational orientation of a load, the method comprising:
coupling a housing or framework to the load;
coupling a motorized frictionless swivel directly or indirectly to the housing or framework and to one or more lines suspending the load;
mounting one or more thrusters movably directly or indirectly to the housing or framework via one or more mounting elements to vary a position of the one or more thrusters from a centre of the housing or framework; and
controlling the rotational orientation of the load by controlling a proportion of rotational force applied to the load from the motorized frictionless swivel and the one or more thrusters by a controller in communication with the motorized frictionless swivel and the one or more thrusters.
Suitably, the method comprises mounting at least one torque generating device to the housing or framework and controlling a proportion of rotational force applied to the load from the at least one torque generating device via the controller in communication with the at least one torque generating device.
Suitably, the at least one torque generating device is selected from the following: a gyroscope; a gyroscopic module, unit or device; a control moment gyroscope (CMG); a flywheel; a rotating mass, such as, but not limited to a mass of fluid moved around an enclosed void, or other rotational device capable of imparting torque on the load.
In some embodiments, the orientation control apparatus comprises a torque generating device in the form of one or more drag elements or mechanisms to create drag in the presence of wind. Suitably, a position and/or an orientation of the one or more drag elements or mechanisms is adjustable to vary the drag, and therefore the torque generated by the one or more drag elements or mechanisms.
Suitably, the one or more drag elements or mechanisms is coupled to the load and is offset from the centre of the housing or framework.
Suitably, the one or more drag elements or mechanisms are coupled to be in communication with the controller and a power source.
In some embodiments, the one or more drag elements or mechanisms comprises one or more slats or plates.
Suitably, the one or more slats or plates are mounted to a rotatable rod or bar or the like driven by a drive means such that an orientation of the one or more drag elements or mechanisms is adjustable to vary the drag, and therefore the torque generated by the one or more drag elements or mechanisms.
Suitably, an angle of incidence of the one or more slats or plates to the wind can be adjusted about the axis of the rod or bar to vary a coefficient of drag of the one or more slats or plates relative to the wind thus varying the torque about the centre of the load due to the drag.
In some embodiments, a position of the one or more drag elements or mechanisms from the centre of the load is adjustable or variable.
Suitably, the motorized frictionless swivel comprises a top section or stator within which a bottom section or rotor rotates relative to the top section or stator on a thrust bearing, and a drive means to rotate the bottom section relative to the top section.
In some embodiments, the apparatus further comprises one or more sensors in communication with the controller to measure a rate of rotation of the top section or stator and the bottom section or rotor of the motorized frictionless swivel.
In some embodiments, the apparatus further comprises one or more sensors in communication with the controller to measure a rate of rotation of a crane boom.
Suitably, the motorized frictionless swivel is used for one or more of the following: to reduce the load for starting rotation of the load; to reduce the load for maintaining rotation of the load; for braking; for holding the load in a set orientation.
Further aspects and/or embodiments and/or features of the present invention will become apparent from the following detailed description.
In order that the invention may be readily understood and put into practical effect, reference will now be made to preferred embodiments of the present invention with reference to the accompanying drawings, wherein like reference numbers refer to identical elements. The drawings are provided by way of example only, wherein:
Skilled addressees will appreciate that elements in the drawings are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the relative dimensions of some of the elements in the drawings may be distorted to help improve understanding of embodiments of the present invention. Some of the elements of the apparatus may be omitted from some of the drawings to aid clarity.
Embodiments of the present invention are directed to improved arrangements for rotational apparatus, and in particular to orientation control apparatus for controlling the rotational orientation of larger loads suspended from the apparatus, and associated methods.
According to some embodiments, the orientation control apparatus comprises a supplementary source of torque to provide gross and fine control of rotational position of loads. According to some embodiments, the supplementary source of torque is a fan, or multiple fans, or other types of thrusters, that have the characteristic of constant thrust, hence torque, and have an increased effect with increased distance from the centre of gravity.
According to some embodiments, the orientation control apparatus comprises a mechanical drive between a crane hook and an upper part of a swivel of the crane hook to force relative rotation between the hook and a hook block, effectively eliminating, on demand, the friction inherent in the swivel of the crane hook.
According to some embodiments, the orientation control apparatus comprises a controller or control system to control a proportion of rotational force applied to the load from different components of the apparatus or system that provide torque to achieve useable control of very large loads. Components of the system contribute rotational force as required in a closely controlled manner. The controller or control system optimises all aspects of the components to provide the most effective orientation output and control under a wide variety of loads and a range of environmental conditions. The different characteristics of each of the components providing rotational force, such as one or more torque generating devices, such as one or more gyroscopes or gyroscopic modules/units/devices, a powered swivel and one or more fans/thrusters, provide a high degree of freedom in configuring the complete system for flexibility and scalability.
According to some embodiments, the orientation control apparatus comprises a sub-module of the control system to: a) use one or more fans to reduce load swing, for example in offshore environments, where the tip of the crane is moving because a ship upon which it is mounted is moving; b) provide a damping effect by cycling the one or more fans off and on; c) direct application of thrust for lateral/longitudinal travel in addition to, or instead of rotation.
According to some embodiments, the orientation control apparatus comprises a power supply, for example, to achieve useable control of very large loads over extended periods that can possibly be encountered. According to some embodiments, one or more energy sources can be used, such as diesel-powered generators and/or high-performance batteries. Another option is to use an external power source, for example, to spin up the torque generating device, such as the gyroscope/gyroscopic module before the lift and revert to an onboard power source during the lift. A further option is to use the energy stored in gyroscopic rotors at times to feed back into the system for use in the other devices.
Embodiments of the present invention provides a viable method of minimising human input into suspended load handling over a much wider range of load types and environmental conditions.
With reference to
According to some embodiments as shown in
The orientation control apparatus 100 comprises a power supply or power source 132 coupled to the at least one torque generating device 106, the one or more thrusters 108, the mounting elements 110 and the motorized frictionless swivel 116.
According to other embodiments, the orientation control apparatus 100 for controlling rotational orientation of the load 102 suspended from the apparatus 100 comprises the housing or framework 104 for coupling to the load 102, at least one torque generating device 106 mounted to the housing or framework, the motorized frictionless swivel 116 coupled directly or indirectly to the housing or framework 104 and to one or more lines 118 suspending the load and the controller 114. In such embodiments, the controller 114 is in communication with the at least one torque generating device 106 and the motorized frictionless swivel 116 to control a proportion of rotational force applied to the load 102 from the at least one torque generating device 106 and the motorized frictionless swivel 116 to control the rotational orientation of the load 102.
According to further embodiments, the orientation control apparatus 100 for controlling rotational orientation of the load 102 suspended from the apparatus 100 comprises the housing or framework 104 for coupling to the load 102, the motorized frictionless swivel 116 coupled directly or indirectly to the housing or framework 104 and to one or more lines 118 suspending the load, the one or more thrusters 108 movably mounted directly or indirectly to the housing or framework 104 via one or more mounting elements 110 to vary a position of the one or more thrusters 108 from a centre of the housing or framework 104 and the controller 114. In such embodiments, the controller 114 is in communication with the motorized frictionless swivel 116 and the one or more thrusters 108 to control a proportion of rotational force applied to the load 102 from the motorized frictionless swivel 116 and the one or more thrusters 108 to control the rotational orientation of the load 102.
Hence, different embodiments of the orientation control apparatus 100 of the present invention comprise different combinations of sources of rotational force, or torque, which are individually controlled in concert to provide the desired rotational force, or torque, to control the rotational orientation of the load according to the particular application.
The one or more movable mounting elements 110 to vary the position of the one or more thrusters 108 can be in the form of telescoping frames or arms, as shown in
The one or more thrusters 108 can be in the form of fans, such as bi-directional fans, fixed pitch fans, variable pitch fans, single speed fans, variable speed fans, direct thrust fans, vectored thrust fans and can be, for example, petrol or battery powered. The fans can be self-contained in that they have their own power supply, or powered from a central power source 132 of the orientation control apparatus 100. In other embodiments, a hybrid power supply is used wherein the orientation control apparatus 100 comprises an on-board battery that charges while connected to a power and control hub that does not form part of the orientation control apparatus 100.
With reference to
There are various loads that must be overcome by the rotational mechanism(s) controlling suspended load orientation. Such loads comprise the rotational inertia of the load, which is a function of the load characteristics and is stable. Such loads also comprise the torques due to friction in the crane hook swivel and unbalanced wind pressure on the load 102 and rigging, which are both variable. The relative contributions of the two externally originating effects vary in accordance with wind speed and the ratio of load inertia to the area of the one or more drag elements or mechanisms 138 comprising one or more slats or plates 140, as described herein.
In the absence of wind effects, the friction in the swivel is the only reason for the load 102 to stop rotating after the rotational mechanisms have caused it to start rotating. If sufficient torque can be applied to the rotating bottom section or rotor 124 of the crane hook relative to the non-rotating top section or stator 122, the effect of swivel friction can be cancelled out, and a load 102 that has been made to rotate will continue to rotate without requiring additional input from the primary rotational mechanisms. If a control system is configured to take inputs from both the upper and lower sections of the hook in terms of rate and direction of rotation, the torque applied to rotate the bottom section or rotor 124 of the hook will cause it to rotate at the same rate as the rotational mechanisms are moving the suspended load 102. Once this is achieved the swivel can effectively be frictionless with respect to the rotational mechanism.
In the presence of unbalanced wind loads that are reducing the ability of the rotational mechanism to rotate the load, torque applied by the motorized swivel 116 can be used to augment the torque being generated by the rotational mechanism, by having the torque applied to the bottom section or rotor 124 of the hook to be greater than that required to overcome swivel friction, in which case the motorized swivel 116 will increase the effective rotational capacity of the rotational mechanism.
Conversely, if the load 102 is rotating and is required to be slowed or stopped, applying torque to the bottom section or rotor 124 of the hook relative to the top section or stator 122 in the reverse direction will assist in bringing the load 102 to a stop, effectively increasing the braking ability of the rotational mechanism.
In all cases the torque generated by the motorised swivel 116 cannot result in torque applied to the crane hoist rope (or ropes) in excess of their torsional stiffness, although some limited amount of twist is acceptable. Sensors 136 on the non-rotating top section or stator 122 of the hook monitor if the hoist ropes are approaching the limit of allowable twist. Additional sensors (not shown) on the crane boom would be required to allow a compensation to be made if the crane was slewing, which would otherwise give an incorrect reading on actual hoist rope twist.
In summary, having the ability to provide torque between the upper and lower parts of the crane hook can be used to increase the effective rotational capacity of the rotational mechanism(s) at the start, during rotation, for braking, and for holding in a set orientation.
With reference to
With reference to
The pivot point 134 is frictionless, or substantially frictionless due to the motorized swivel 116. The pivot point 134 contributes negligible counter-acting moment to the combined applied moments of the one or more torque generating device 106 and the one or more thrusters 108.
The one or more torque generating device 106 and the one or more thrusters 108 can operate simultaneously, or can operate in relays, whereby the one or more thrusters 108 are used for large rotational angles and the one or more torque generating device 106, such as gyroscope or gyroscopic module is then deployed for final fine or precision orientation of the load.
With reference to
The orientation control apparatus 100 of the present invention can be operated in a variety of operating modes. For example, all force/torque elements, i.e. the one or more torque generating device 106, the one or more thrusters 108 and the motorized frictionless swivel 116 can be operated together. Alternatively, a subset thereof can be operated in combination. In some operating modes, the one or more thrusters 108 provide wind load offset compensation and the one or more torque generating device 106 control inertia and fine positioning. In some operating modes, the one or more thrusters 108 hold the load while allowing the one or more torque generating device 106 to re-set to vertical for an optimal control position. In some operating modes, a combination of the force/torque elements are used working with a crane control system to provide full positional and rotational management. For example, the orientation control apparatus 100 of the present invention can be make it appear that a load, such as a turbine blade is rotating in the horizontal plane about a point that is not at the centre of gravity, by combining the slew and luff motions of the crane boom with the orientation motion from the one or more gyroscope or gyroscopic module 106 and the one or more thrusters 108.
According to other aspects or forms, the invention resides in methods of controlling rotational orientation of the load 104. With reference to
With reference to
The one or more drag elements or mechanisms 138 can be used as a substitute for the one or more thrusters 108 or the one or more torque generating devices 106, such as the gyroscopic modules, or in addition to the one or more thrusters 108 or the torque generating device 106, such as a gyroscopic module. The one or more thrusters 108 have been omitted from
Hence, embodiments of the present invention address or at least ameliorate at least some of the aforementioned problems. For example, the orientation control apparatus 100 according to embodiments of the present invention comprises one or more supplementary source of rotational force, or torque to provide additional rotational control to that provide by a primary source of torque in the form of one or more torque generating device 106, that is particularly effective in controlling rotational motion of large and/or heavy loads. According to some embodiments, the one or more supplementary source of rotational force, or torque is in the form of one or more drag elements or mechanisms 138 and/or one or more thrusters 108, which provide constant thrust and hence torque, that have an increased effect with increased distance from the centre of gravity. The one or more thrusters 108 are movable via one or more mounting elements 110 to provide selectivity in the distance from the centre of gravity and thus the moment provided by the one or more thrusters 108. According to some embodiments, the one or more supplementary source of rotational force, or torque is in the form of the motorized frictionless swivel 116, which can be used in conjunction with, or instead of, the one or more thrusters 108. Various modes of operation as described herein provide further flexibility and adaptability regarding controlling rotational orientation of a suspended load via the orientation control apparatus 100.
In this specification, the terms “comprises”, “comprising” or similar terms are intended to mean a non-exclusive inclusion, such that an apparatus that comprises a list of elements does not include those elements solely, but may well include other elements not listed.
Throughout the specification the aim has been to describe the invention without limiting the invention to any one embodiment or specific collection of features. Persons skilled in the relevant art may realize variations from the specific embodiments that will nonetheless fall within the scope of the invention. For example, it is envisaged that one or more features from two or more embodiments described herein can be combined to form one or more further embodiments.
Number | Date | Country | Kind |
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2019902777 | Aug 2019 | AU | national |
Filing Document | Filing Date | Country | Kind |
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PCT/AU2020/050788 | 7/31/2020 | WO |