Patent Application
20210122616
The present disclosure relates generally to devices for lifting loads.
“Below the hook” (BTH) devices are used for attaching a load to hoist. A common BTH device is known as a “lifting beam,” although BTH devices may also include components such as slings, hooks, and rigging hardware. BTH devices are designed in many shapes and sizes to accomplish different types of lifts and include, but are not limited to, lifting beams, spreader bars, “C” hooks, sheet lifters, and beam clamps. BTH lifting devices such as lifting beams are typically constructed of a metal, such as steel or aluminum. Guidelines for the design of BTH devices can be found in ASME BTH-1. Safety standards for BTH devices can be found in ASME B30.20. A BTH lifting device may be marked with an ASME defined service tag that provides loading guidance (e.g., a maximum number of lifts, or maximum lift load limit) and inspection guidance (e.g., timelines for periodic inspection).
Unfortunately, whether accidentally or by users engaging in unsafe practices, such guidance may not always be followed or tracked, and approximations may be improperly substituted. For example, the safe-lifting (maximum load) capacity of a BTH device may be exceeded. In such situations, the BTH device could experience a component failure or fatigue more than expected (thereby shortening or ending its service life), and an inspection of the BTH device may be warranted. Without monitoring or tracking, such loading may occur and/or such inspection may not occur unnoticed. Also, users of BTH devices who rely on calculating an expected amount of lifts during service rather than counting actual amount of lifts may take a BTH device out of service earlier than it needs to be or may leave the BTH device in service beyond its approved service life. Further, users may not accurately track due dates for ASME mandated periodic inspection (e.g., monthly, yearly) of particular BTH devices. Managing data related to lift limits and inspections is more complicated in larger facilities, perhaps more so in organizations with multiple locations, where many BTH devices are in use.
In view of the above, a lifting device, system, and method of use that addresses one or more drawbacks of existing devices, systems and methods, or one or more other issues, would be welcome.
Aspects and advantages of the disclosed subject matter will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the disclosed subject matter. In some aspects, the disclosed subject matter includes a smart lifting device, a system, and a related and method for evaluating a duty cycle status of a lifting device suspendable from a support for lifting loads.
A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
Generally speaking, the present disclosure is directed to lifting devices for lifting loads, wherein data regarding the lifting can be monitored and gathered.
As illustrated, lifting device 20 includes a base member 28 and a lift monitor 30 attached to the base member and suspendable from the support 22,24. One or more sensors, discussed below, are associated with lifting device 20 so as to obtain data regarding loads being lifted. The sensor, lift monitor 30, and base member 28 are configured so that the mass of the base member and the mass of the load 26 act upon and are supported by the sensor(s) during lifting. In other words, the sensor(s) are exposed to and carry forces of load 26 and base member 28 during a lift.
The sensor(s) determine parameters related to lifting of load 26. As will be discussed below, parameters related to lifting sensed by the at least one sensor may include one or more of an instance of lifting, a force generated during an instance of lifting, and/or an acceleration generated during an instance of lifting.
Lifting device 20 further includes a reporting system for providing information related to the determined parameters. The reporting system may include elements located within or attached to lift monitor 30 and/or base member 28, as well as remotely located elements, and may include one or more of wired or wireless communications devices, display devices, input-output devices, computers, microprocessors, memory, software, variable and fixed databases and lookup tables, etc.
Base member 28 may be a one-piece or multi-piece beam or the like suitable for lifting loads of a desired mass. Base member 28 may thus be made from one or more pieces of a metal such as a steel alloy or an aluminum alloy, may be assembled using fasteners, and/or may include welds, etc. As illustrated in
Base member 28 may also include one or more openings 38 for receiving a connector for attachment to an element of lift monitor 30 with internal or external sensor(s). Opening 38 may be centrally located and the connector may be a shackle 40, as illustrated. Alternately (not shown), the connector may be part of lift monitor 30. In another alternative (not shown), multiple openings 38 could be employed for attachment to a flexible structure such as a chain or cable or to a rigid structure for lifting base member 38 from above, with lift monitor 30 located between such flexible or rigid structure and the support so as to be exposed to lifting forces. As another alternative (see
As noted, device 20 includes at least one sensor associated with lift monitor 30 for determining a parameter of lifting of a load. If desired, such sensor may be inside of or attached to lift monitor 30, and may include a load cell for determining a force load (in tension) seen by base member 28. As illustrated in
The at least one sensor may also include an accelerometer 52 for measuring a vertical acceleration at lift monitor 30. Vertical acceleration may, if desired, be taken into account in evaluating whether a lift meets certain predetermined force parameters apart from those simply generated by mass and gravitational force. For example, forces generated by vertical acceleration may be entirely discounted, may be clipped and therefore discounted if not above a certain range or lasting beyond a certain time duration, and may thus be partially or wholly subtracted from the force measured and reported by load cell 42. Also, two parameters may be noted: force measured and reported by load cell 42 and such force modified in view of accelerometer readings.
Before discussing operation of lifting device and a system utilizing it, other elements of lifting device should be noted. For example, lift monitor 30 also includes a housing 54 holding and protecting such sensor elements 42, 52. Also within housing is a power source, such as a battery 56, and if desired onboard battery charger circuitry 58. Alternatively, a plug for connection to external charger could be provided, solar charging, wireless charging, etc. could be employed to charge battery 56. Alternatively, battery 56 could be avoided and power could be provided via an electrical cable to lift monitor, or any combination of AC or DC power could be employed, as desired. (Note that for simplicity and clarity in the drawings conventional electrical connections between elements such as load cell 42, battery 56, etc., and some walls of housing 54 are not illustrated in
A printed circuit board (PCB) 60 is mounted within housing 54 and holds electronics such as a microcontroller having a processor and a memory storing code for operating lift monitor 30 and its components such as its sensors, input output devices, wired or wireless (WiFi/cellular/GSM/Bluetooth/RFID/GPS) communications devices, etc. An amplifier 62 may be electrically connected to an output of load cell 42 and mounted on or adjacent PCB 60 for receiving and amplifying the signal from load cell 42 so as to be usable by microcontroller and lifting device 20 in general.
Display 64 may be attached to housing 54 to provide a user alphanumeric or pictographic information regarding the status of lift monitor 30 and/or base member 28. One or more dedicated indicators such as LED's 66,68,70 may also be provided to give a user information. Such indicators may be of different colors (e.g., green, yellow, red) or may be illuminated, flash, in different patterns, etc., to indicate different things to the user, as desired. An audible signaling device 72 such as a buzzer, vibrator, speaker, etc. may also be provided to give the user feedback as to status of lift monitor 30 and base member 28. One or more i/o elements 74,76 such as buttons, switches, keypads or the like may be employed on housing 54 to allow a user to turn lift monitor on or off, or to select and vary different device settings, clear onboard memory, rest or reset device, communicate with a remote computer or other device within system, etc. As an alternative to an off/on button or the like, housing may also use accelerometer 52 or a vibration sensor 82 to “wake up” lift monitor. If desired, the microcontroller on PCB 60 may include a clock function 84 to shut down or “sleep” onboard electronics if no motion and/or i/o element function is sensed after a given period of time.
Thus, display 64, indicators 66,68,70, signaling device 72 are part of a reporting system for providing a user information regarding the status of the lifting device, a current lift, a history of lifts (whether within or outside of desired protocols), etc. However, such reporting system may also or alternatively include elements spaced from lift monitor 30 and base member 28. For example, a first computer 78 may be in communication with lift monitor 30 via wired or wireless communication (WiFi, cellular, GSM, Bluetooth, RFID, GPS, etc.). First computer 78 may be a general purpose computer such as a workstation, laptop, or the like, a dedicated computer, a smart phone or other device, either at or near a location in which lift monitor is located, or at a remote location. First computer 78 may also be a local or remote server that maintains a database of information regarding one or more lift monitors and base members. Second computer 80 may also include a general purpose computer such as a workstation, laptop, or the like, a dedicated computer, a smart phone or other device, housing dedicated software and/or providing an internet connection so as to, via wired or wireless connection, monitor and manipulate data in the database, configure a system including one or more lift monitors and base members, provide periodic or live status reporting, to provide error, overload, or inspection reporting, etc. If desired, first and second computers can be the housed at the same or different locations, and the functions of first and second computers can be met by a single computing device. In applications and systems where multiple base members are in use, first computer and/or second computer can be employed to manage all such base members via their related lift monitors.
Thus, in use a memory on PCB 60 and/or within first or second computers 78,80 may increment and store a lift count based on the detected instance of lifting, as sensed by the at least one sensor (load cell 42 with or without input from accelerometer 52). Such memory may store a predetermined lift count limit, and the reporting system (indicators, first and second computers) indicates when the lift count reaches the predetermined lift count limit. The predetermined lift count limit may for example indicates need for at least one of inspection of the lifting device, maintenance of the lifting device, and retirement of the lifting device.
Depending on the application, and the characteristics of the base member such as from which what alloy of which metal it is made, the incrementing may be different. For example, for aluminum, all lifts may require incrementing, whereas for steel, only lifts above a minimum force amount may require incrementing. Such information can be stored in the computer 78/80 database and/or stored onboard on the memory within the lift monitor 30. Thus, where the sensor includes load cell 42 for detecting a force generated at the lift monitor during an instance of lifting, and the memory stores the detected force, the memory may also store a predetermined force limit, with the reporting system indicates when the detected force reaches the predetermined force limit stored in the memory. The lift count may only be incremented when the detected force reaches the predetermined force limit stored in the memory to avoid counting lifts that do not fatigue base member 28. By avoiding counting all lifts, unnecessary inspection and/or unnecessarily early retirement of base member 28 may be avoided. Again, such force may be calculated with or without factoring in input from accelerometer 52. By utilizing accelerometer 52, certain lifts that appear to exceed rated limits may be determined to be within limits, either maximums (safety limits) or minimums (sufficient for incrementing). Thus, if some “within-safe-limits” lifts can be excluded in spite of nominal load cell readings, then useful life of the base member can be extended and unnecessary inspections can be avoided. Regardless, by using the load cell (and possibly also the accelerometer) and transmitting the detected information to an onboard or remote memory along with base member identification/location information, a robust and detailed history of use of base member 28 is made possible that previous devices could not provide.
If desired, multiple clevis pin type load cells could be employed at locations that provide an additive total load between overhead structures and load. Thus, pins 142b and 142c, respectively attached to hooks 136 or other structure beneath ends of base member to which load is attached, may include clevis pin type load cells. Total loading experienced at pins 142b and 142c could be measured and used as noted above.
One or more clevis pin type load cells (not shown) could also be employed within lift monitor 130 with above and below connections modified accordingly so that total loading is obtained. Alternatively multiple load cells could be attached in a way that more than one are subject to full load, and the loading noted is compared, averaged, etc.
Depending on the location of the load cell(s), communication connection to lift monitor may be wired or wireless. If wireless a separate power and communication system for the load cell(s) may be required and a receiver function may be required for the lift monitor, along the lines discussed above.
The lifting devices of the present disclosure can be used to perform various methods, including a method for evaluating a duty cycle status of a lifting device suspendable from a support for lifting loads, the method comprising the steps of: attaching a load 26 to a base member 28/128/228; lifting the base member and the load using the support 22,24; monitoring parameters related to the lifting step using a lift monitor 30/130/230 attached to the base member 28, and having at least one sensor 42, the at least one sensor detecting at least an instance of lifting; and reporting information related to the determined parameters.
The method can include other options such as incrementing and storing a lift count based on the detected instance of lifting, and/or indicating when the lift count reaches a lift count limit. The sensor may detect a force generated during an instance of lifting, and the device may only then indicate when the detected force reaches a predetermined force limit. The predetermined force limit is dependent in part on a characteristic of the base member, and the characteristic may be a material of the base member. The lift count may be incremented only when the detected force reaches the predetermined force limit.
The at least one sensor may detect an acceleration generated during an instance of lifting. The device may then calculate using the detected force and the detected acceleration whether the predetermined force limit has been reached. For example, forces cause by movement/acceleration (not gravity) may be excluded from the determination by subtracting same from the output of the load cell. The lift count may be incremented by an increment amount only if calculating step determines that the detected force has reached the predetermined force limit.
In the methods of use, a duty cycle lift limit is assigned to the base member, the duty cycle lift limit being recalculated in view a difference of a number of instances of lifting and the increment amount. The duty cycle lift limit may be assigned to the base member, the duty cycle lift limit being recalculated (either by adjusting upward the lift limit or by excluding certain lifts to calculate a lower qualifying lift total—the result is the same in terms of remaining lift lifespan) in view a cumulative amount of force of all instances of lifting.
The method may include displaying on a display the information related to the determined parameters, and the display may be attached to the lift monitor, or on a station located remotely from the lift monitor, the method further including wirelessly communicating the information related to the determined parameters to be displayed on the display. In a larger system at one or more locations, a plurality of the base members may be employed each having a respective lift monitor in wireless communication with the station. Each of the lift monitors may communicate an identity via the communications system so that the computer can centrally monitor the parameters related to lifting of the load for each of the base members.
The disclosed device and methods thus provide multiple separately or collectively useful benefits and functions. The lift monitor may be retrofitted onto existing devices or used with new base members. Base members can be accurately tracked, warnings and notices can be provided, and the useful life of a lift member can be optimized using the collected and evaluated information. By incorporating acceleration information, more accurate information about loads lifted can be obtained. Minimum lift forces suitable for incrementing and maximums suitable for safety warnings can be noted and logged. A database of maximum lift weights, dates and times, and lift member identity can be reliably tracked, all remotely if desired. Large populations of lift members can be tracked and monitored so as to achieve certainty and efficiency, all using one or more aspects of the above devices and methods.
It should be appreciated by those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope and spirit of the disclosure. It is intended that the present disclosure include such modifications and variations as come within the scope of the appended claims and their equivalents.
The present application is a Non-Provisional Patent Application and claims priority to U.S. Provisional Patent Application Ser. No. 62/927,312, filed Oct. 29, 2019, which is incorporated by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| 62927312 | Oct 2019 | US |
