Patent Application
20220185639
This application relates to a wireless hoist system and is directed to wirelessly controlling hoist devices for moving workpieces as well as other hoist systems.
Hoist devices are used for lifting or lowering workpieces. The hoist devices may be manually operated, electrically or pneumatically driven, and may use chain or chain rope to move the workpieces.
For complex movements, precise placements, or moving complex objects (for example, in terms of weight distribution and shape), two or more hoist devices can be used to move the workpiece from one location to another location. The hoist devices may be moved in a coordinated manner by multiple users to ensure that the workpiece is not damaged. However, without communication between the hoist devices, the hoist systems are prone to user error in coordinating the hoist devices.
One embodiment provides a wireless hoist system including a first hoist device having a first motor and a first wireless transceiver and a second hoist device having a second motor and a second wireless transceiver. The first hoist device and the second hoist device are configured to be coupled to a workpiece to raise or lower the workpiece. The wireless hoist system also includes a controller in wireless communication with the first wireless transceiver of the first hoist device and the second wireless transceiver of the second hoist device. The controller is configured to receive user input and determine a first operation parameter and a second operation parameter based on the user input. The controller is also configured to provide, wirelessly, a first control signal indicative of the first operation parameter to the first hoist device and provide, wirelessly, a second control signal indicative of the second operation parameter to the second hoist device. The first hoist device operates based on the first control signal and the second hoist device operates based on the second control signal.
In some examples, the controller communicates with the first hoist device over a first wireless channel and wherein the controller communicates with the second hoist device over a second wireless channel.
In some examples, the system further comprises a third hoist device, and the first hoist device is further configured to: determine a third operation parameter based on the first operation parameter; and provide a third control signal indicative of the third operation parameter to the third hoist device, wherein the third hoist device operates based on the third control signal.
In some examples, the controller communicates with the first hoist device over a first wireless channel, and the first hoist device communicates with the third hoist device over a second wireless channel.
In some examples, the first hoist device further comprises: a chain connectable to the workpiece to raise and lower the workpiece, the first motor coupled to the chain to release and retract the chain; a sensor for detecting a chain length of the chain indicative of a length of chain released from the first hoist device; and a motor drive coupled to the sensor and the motor and configured to: receive the chain length from the sensor; receive the first control signal from the controller; and drive the motor based on the first control signal and the chain length.
In some examples, the motor drive is further configured to: receive a level input from a level, the level placed on the workpiece and the level input indicating an angle of the level with respect to ground, wherein driving the motor is further based on the level input.
In some examples, the controller is further configured to: receive a level input from a level, the level placed on the workpiece and the level input indicating an angle of the level with respect to ground, wherein determining the first control signal and the second control signal are further based on the level input.
In some examples, the first operation parameter includes one or more selected from a group consisting of: speed, direction, and chain length.
In some examples, the user input is a desired movement of the workpiece.
In some examples, the user input includes a position of the first hoist device, a position of the second hoist device, and a desired end position of the workpiece.
Another embodiment provides a wireless hoist system including a first hoist device having a first motor and a first wireless transceiver and a second hoist device having a second motor and a second wireless transceiver. The first hoist device and the second hoist device are configured to be coupled to a workpiece to raise or lower the workpiece. The wireless hoist system also includes a controller in wireless communication with the first wireless transceiver of the first hoist device and the second wireless transceiver of the second hoist device. The controller is configured to receive user input and determine a first operation parameter based on the user input. The controller is also configured to provide, wirelessly, a first control signal indicative of the first operation parameter to the first hoist device and provide, wirelessly, a second control signal indicative of the first operation parameter to the second hoist device. The first hoist device operates based on the first control signal and the second hoist device operates based on the second control signal.
In some examples, the first control signal is provided to the first hoist device in response to determining that a first channel associated with the first hoist device is enabled, and the second control signal is provided to the second hoist device in response to determining that a second channel associated with the second hoist device is enabled.
In some examples, the system further comprises a third hoist device including a third motor and a third wireless transceiver, and the third hoist device is associated with a third channel. Further, the controller, in response to determining that the third channel is disabled, does not provide a control signal indicative of the first operation parameter to the third hoist device.
Another embodiment provides a wireless hoist system including a first hoist device having a first motor and a first wireless transceiver. The first hoist device is configured to be coupled to a workpiece to raise or lower the workpiece. The wireless hoist system also includes a level configured to be placed on the workpiece, to sense an angle of the level with respect to gravitational pull when the level is on the workpiece and to wirelessly output a level signal indicative of the angle. The wireless hoist system further includes a controller in wireless communication with the first wireless transceiver of the first hoist device and the level. The controller is configured to receive user input and determine a first operation parameter based on the user input. The controller is also configured to receive the level signal and provide, wirelessly to the first hoist device, a first control signal that is based on the first operation parameter and the level signal. The first hoist device operates based on the first control signal.
In some examples, the system further comprises a second hoist device including a second motor and a second wireless transceiver, and the second hoist device is configured to be coupled to the workpiece to raise or lower the workpiece. Further, the controller is configured to: determine a second operation parameter based on the user input, and provide, wirelessly to the second hoist device, a second control signal that is based on the second operation parameter and the level signal. Further, the second hoist device operates based on the second control signal.
Another embodiment provides a wireless hoist system including a first hoist device having a first motor and a first wireless transceiver and a second hoist device having a second motor and a second wireless transceiver. The second wireless transceiver is in wireless communication with the first wireless transceiver and the first hoist device and the second hoist device are configured to be coupled to a workpiece to raise or lower the workpiece. The wireless hoist system also includes a controller in wireless communication with the first wireless transceiver of the first hoist device. The controller is configured to receive user input and determine a first operation parameter based on the user input. The controller is also configured to provide, wirelessly, a first control signal indicative of the first operation parameter to the first hoist device. The first hoist device is configured to provide, wirelessly, a second control signal to the second hoist device and the second control signal is based on the first control signal. The first hoist device operates based on the first control signal and the second hoist device operates based on the second control signal.
In some examples, the first wireless transceiver, the second wireless transceiver, and the controller communicate via an RF communication protocol. The RF communication protocol uses dual identifiers, one broadcast from the controller, and an individual identifier for each of the first wireless transceiver and the second wireless transceiver.
In some examples, the RF communication protocol initiates a pairing between the controller and the first wireless transceiver. The pairing includes broadcasting a first pairing signal from the controller to the first wireless transceiver, wherein the first pairing signal includes an identifier of the controller, and storing, at the first wireless transceiver, the identifier of the controller. The pairing also includes transmitting, by the first wireless transceiver in response to receiving the pairing signal, an identifier of the first wireless transceiver, storing at the controller the identifier of the first wireless transceiver, and generating a paired identifier including at least the identifier of the controller and the identifier of the first wireless transceiver for performing future communications between the controller and the first wireless transceiver.
In some examples, the RF communication protocol initiates a pairing between the controller and the second wireless transceiver. The pairing includes broadcasting a second pairing signal from the controller to the second wireless transceiver, wherein the second pairing signal includes an identifier of the controller, and storing, at the second wireless transceiver, the identifier of the controller. The pairing also includes transmitting, by the second wireless transceiver in response to receiving the pairing signal, an identifier of the second wireless transceiver, storing at the controller the identifier of the second wireless transceiver, and generating a paired identifier including at least the identifier of the controller and the identifier of the second wireless transceiver for performing future communications between the controller and the second wireless transceiver.
Another embodiment includes a hoist device having a power source, a motor having an output shaft, a transmission coupled to the output shaft, and a controller configured to control an operation of the motor. The transmission is configured to interface with a chain, and to transfer rotational motion of the output shaft of the motor to the chain to one of release or retract the chain. The hoist device is configured to one of raise and lower a workpiece coupled to the chain based on a user command signal received at the controller
In some examples, the hoist device also includes a limit sensor configured to detect an end of the chain. The limit sensor is further configured to provide an input to the controller to stop the motor in response to detecting the end of the chain.
In some examples, the limit sensor is one or more of a mechanical limit switch, a hall sensor, a time-of-flight sensor, a chain speed sensor, an ultrasonic pulse transceiver, and a distance run sensor.
In some examples, the limit sensor is configured to detect a change in the size of one or more links in the chain indicating the end of the chain.
In some examples, the limit sensor is configured to detect a change in the color of one or more links in the chain indicating the end of the chain.
In some examples, the limit sensor is a mechanical limit switch configured to be actuated by a feature of the chain used to indicate the end of the chain.
In some examples, the hoist device includes a wireless transceiver and a remote controller in communication with the wireless transceiver.
In some examples, the controller is configured to determine a distance between the hoist device and the remote controller using a distance determination protocol. The distance determination protocol includes receiving, from the remote controller, a data packet including a sent time message, determining a receive time at the data packet using the controller, and determining a distance between the remote controller and the hoist device. The distance is determined based on the speed of the transmission and the difference between the receive time and the sent time.
In some examples, a first internal clock of the remote controller and a second internal clock of the controller are synchronized.
In some examples, the remote controller includes a display device configured to display one or more parameters associated with the hoist device.
In some examples, the parameters include one or more of an overload condition, an ability to complete lift condition, a system health, an individual hoist battery charge level, a remote battery charge level, a secured load indication, and a distance between the hoist device and the remote controller.
In some examples, the remote controller further includes an input to provide a variable speed input to the controller for controlling a speed of the motor.
In some examples, the controller is additionally configured to determine a magnitude of a load associated with the workpiece, and control a rate of acceleration of the motor based on the determined magnitude. The rate of acceleration is reduced in response to an increase in the magnitude of the load.
In some examples, the hoist device includes a load detection device in communication with the controller.
In some examples, the load detection device is a hydraulic cylinder coupled between the hoist device and a hoist support point, the hydraulic cylinder including a pressure sensor in communication with the controller.
In some examples, the pressure sensor outputs a pressure reading indicative of a load coupled to the hoist device.
In some examples, the load detection device is a load cell coupled between the hoist device and a hoist support point, the load cell configured to communicate a load reading to the controller.
In some examples, the load detection device is a current sensor configured to determine a current consumption of the motor, wherein the current consumption is indicative of a load coupled to the hoist device.
In some examples, the load detection device is a speed sensor configured to determine a speed of the motor and in communication with the controller. The controller is configured to determine a load based on a decrease in speed of the motor from a no-load speed.
In some examples, the hoist device further includes a load hook coupled to a first end of the chain. The load hook is configured to couple the workpiece to the chain.
In some examples, the load hook includes a security hasp. The security hasp comprises an electronic sensor to determine whether the hasp has been closed.
In some examples, the load hook includes a motion sensor configured to determine a change in a balance of the workpiece when the workpiece is suspended.
In some examples, the motion sensor is one or more of an accelerometer and a gyroscope.
In some examples, the controller is further configured to determine a number of lifts remaining in the power supply based on one or more parameters of the power supply, a current draw during a lifting operation, and a voltage drop during the lifting operation.
In some examples, the controller is configured to receive redundant data signals containing commands from the remote controller in communication with the hoist device.
In some examples, the controller monitors the redundant data signals from the remote controller to verify the accuracy of a received command.
In some examples, the controller is configured to evaluate commands received from the remote controller to verify that the commands are within a predetermined specification.
In some examples, the remote controller includes one or more double activation inputs requiring a user to perform two independent actions in order to transmit a command associated with the user actions.
In some examples, the remote controller includes one or more triple activation inputs requiring a user to perform three independent actions in order to transmit a command associated with the user actions.
In some examples, one of the activation inputs is a capacitive hand sensor for sensing the presence of a user's hand.
In some examples, the hoist device includes a mechanical brake configured to stop and maintain a position of the workpiece during a lifting operation or a lowering operation.
In some examples, the mechanical brake is a friction brake.
In some examples, the friction brake is actuated based on a command from the controller.
In some examples, hoist device includes an electro-mechanical brake configured to stop and maintain a position of the workpiece during a lifting operation or a lower operation.
In some examples, the electro-mechanical brake is controller based on an output from the controller.
In some examples, the hoist device includes a chain locking device configured to prevent movement of the workpiece during a loss of power.
In some examples, the chain locking device includes a first pawl configured to engage a first ratchet wheel of the transmission to prevent operation of the hoist device in a first direction.
In some examples, the first pawl is moved into and out of engagement with the first ratchet wheel by one or more solenoid devices.
In some examples, the solenoid is configured to move the first pawl into engagement with the ratchet wheel when power is removed to the solenoid device.
In some examples, the chain locking device further includes a second pawl configured to engage a second ratchet wheel of the transmission to prevent operation of the hoist device in a second direction.
In some examples, the chain locking device includes a worm gear coupled to one or more gears of the transmission to prevent movement of the load by preventing undesired movement of a main drive gear of the transmission.
In some examples, the chain locking device is an inertial lock configured to prevent movement of the chain if a speed of the chain release exceeds a predetermined speed.
In some examples, the controller is configured to stop operation of the hoist device when a voice command indicting a stop is received by one or more components of the hoist device.
In some examples, the controller is configured to determine a distance between the remote controller and the hoist device.
In some examples, the controller is configured to not accept commands from the remote controller when the determined distance exceeds a predetermined threshold.
In some examples, the remote controller uses a line-of-sight communication signal to communicate with the hoist device.
In some examples, the hoist device further includes a manual hoist input configured to accept a manual operating mechanism. The manual operating mechanism interfaces with one or more ratcheting interfaces of the transmission to allow a user to manually raise or lower the workpiece using the manual operating mechanism.
In some examples, the controller is configured to stop an operation of the hoist device in response to determining a current increase that exceeds a predetermined threshold.
In some examples, the controller is configured to stop an operation of the hoist device in response to determining a current decrease that exceeds a predetermined threshold.
In some examples, the power source is a removable battery pack.
In some examples, the removable battery pack is a power tool battery pack.
Other aspects of the application will become apparent by consideration of the detailed description and accompanying drawings.
Before any embodiments are explained in detail, it is to be understood that the included embodiments are not to be limited to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The embodiments are capable of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limited. The use of “including,” “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “mounted,” “connected” and “coupled” are used broadly and encompass both direct and indirect mounting, connecting and coupling. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings, and can include electrical connections or couplings, whether direct or indirect. Additionally, as used herein with a list of items, “and/or” means that the items may be taken all together, in sub-sets, or as alternatives (for example, “A, B, and/or C” means A; B; C; A and B; B and C; A and C; or A, B, and C).
It should be noted that a plurality of hardware and software based devices, as well as a plurality of different structural components may be utilized to implement the described embodiments. Furthermore, and as described in subsequent paragraphs, the specific configurations illustrated in the drawings are intended as example embodiments and other alternative configurations are possible. The terms “processor” “central processing unit” and “CPU” are interchangeable unless otherwise stated. Where the terms “processor” or “central processing unit” or “CPU” are used as identifying a unit performing specific functions, it should be understood that, unless otherwise stated, those functions can be carried out by a single processor, or multiple processors arranged in any form, including parallel processors, serial processors, tandem processors or cloud processing/cloud computing configurations.
It should be understood that although certain drawings illustrate hardware and software located within particular devices, these depictions are for illustrative purposes only. In some embodiments, the illustrated components may be combined or divided into separate software, firmware and/or hardware. For example, instead of being located within and performed by a single electronic processor, logic and processing may be distributed among multiple electronic processors. Regardless of how they are combined or divided, hardware and software components may be located on the same computing device or may be distributed among different computing devices connected by one or more networks or other suitable communication links.
The first hoist device 110A is connected to the workpiece 130 by a first chain 115A of the first hoist device 110A. The second hoist device 110B is connected to the workpiece 130 by a second chain 115B of the second hoist device 110B. The first hoist device 110A and the second hoist device 110B move the workpiece 130 by operating the first chain 115A and the second chain 115B respectively. The first chain 115A and the second chain 115B may be singularly referred to as a chain 115. The hoist controller 120 can control one or more of the first hoist device 110A and the second hoist device 110B (for example, the plurality of hoist devices 110) to move the workpiece 130 between different locations.
In some embodiments, the hoist electronic processor 210 is implemented as a microprocessor with separate memory, such as the hoist memory 220. In other embodiments, the hoist electronic processor 210 may be implemented as a microcontroller (with hoist memory 220 on the same chip). In other embodiments, the hoist electronic processor 210 may be implemented using multiple processors. In addition, the hoist electronic processor 210 may be implemented partially or entirely as, for example, a field-programmable gate array (FPGA), and application specific integrated circuit (ASIC), and the like and the hoist memory 220 may not be needed or be modified accordingly. In the example illustrated, the hoist memory 220 includes non-transitory, computer-readable memory that stores instructions that are received and executed by the hoist electronic processor 210 to carry out functionality of the hoist device 110 described herein. The hoist memory 220 may include, for example, a program storage area and a data storage area. The program storage area and the data storage area may include combinations of different types of memory, such as read-only memory and random-access memory.
The hoist transceiver 230 enables wireless communication between the hoist device 110 and other devices, for example, other hoist devices 110, the hoist controller 120 and the like. In some embodiments, the hoist transceiver 230 includes a combined transmitter and receiver, while in other embodiments, the hoist transceiver 230 includes a separate transmitter and receiver.
The hoist power source 240 may be a DC power source, for example, a power tool battery pack coupled to the hoist device 110, or may be an AC power source, for example, a power cord that plugs into an AC outlet (for example, a wall outlet). In one example, the hoist power source 240 is an M18 REDLITHIUM Battery Pack sold and marketed by Milwaukee®. The hoist power source 240 provides operating electric power to the hoist motor 250 and other electrical components, for example, the hoist electronic processor 210, the hoist transceiver 230, and the like. The electrical connections between the hoist power source 240 and other components of the hoist device 110 are not shown to simplify the illustration. The hoist motor 250 is, for example, an AC motor, a brushless DC motor, a brushed motor, or the like, powered by the hoist power source 240. The hoist motor 250 is controlled by the hoist electronic processor 210 to release or retract the chain 115 from the hoist device 110. The hoist device 110 includes a transmission mechanism for connecting the output shaft of the hoist motor 250 to the chain 115. The one or more hoist sensors 260 include, for example, a length sensor to detect the amount of chain 115 released, a tension sensor to detect the tension in the chain 115, a resolver to detect motor position, a torque or current sensor to detect torque of the hoist motor 250, and the like.
The controller electronic processor 310, the controller memory 320, and the controller transceiver 330 may implemented similarly as the hoist electronic processor 210, the hoist memory 220, and the hoist transceiver 230. The controller transceiver 330 enables wireless communication between the hoist controller 120 and other devices, for example, the plurality of hoist devices 110. The hoist controller 120 and the plurality of hoist devices 110 may communicate over, for example, a Bluetooth network, a Wi-Fi network, or the like. The hoist controller 120 and the plurality of hoist devices 110 may communicate over the same channel or different channels as further described below.
The user interface 340 may include one or more input devices (for example, pushbutton, a trigger, a joystick, a keyboard, and the like), one or more output devices (for example, light emitting diodes (LEDs), a speaker, a display, and the like), and/or one or more input/output devices (for example, a touch screen display). The hoist controller 120 may receive control inputs (for example, a user input) from a user through the user interface 340. For example, the user may move the joystick to control release or retraction of the chain 115 from one or more of the hoist devices 110.
The power source 345 is coupled to and powers the components of the hoist controller 120 including the controller electronic processor 310, the controller memory 320, the controller transceiver 330, and the user interface 340. The electrical connections between the power source 345 and other components of the hoist controller 120 are not illustrated to simplify the illustration. In some embodiments, the power source 345 is a DC power source including, for example, one or more battery cells (e.g., AA type, AAA type, 9V type) or a battery pack including one or more battery cells (e.g., a power tool battery pack or a USB power source). In one example, the power source 345 is an M12 Battery Pack sold and marketed by Milwaukee®. The DC power source, in contrast to a corded AC power source, increases the portability and mobility of the hoist controller 120. However, in some embodiments, the power source 345 is an AC power supply circuit that receives AC power via a cord coupled to an AC power source (e.g., a wall outlet), converts the AC power to DC power (e.g., via a rectifier or power switching elements), and outputs DC power.
The method 700 includes determining, using the controller electronic processor 310, a first operation parameter and a second operation parameter based on the user input (at block 720). The first operation parameter corresponds to the first hoist device 110A and the second operation parameter corresponds to the second hoist device 110B. The controller electronic processor 310 receives the user input, for example, the desired movement of the workpiece, the positions of the hoist devices 110 and the workpiece, and determines the operation parameters of the first hoist device 110A and the second hoist device 110B based on the user input. For example, the controller electronic processor 310 receives a desired movement of the workpiece as the user input and determines a direction and/or speed of movement and/or chain length of the first chain 115A of the first hoist device 110A and a direction and/or speed of movement and/or chain length of the second chain 115B of the second hoist device 110B. The direction and/or speed of movement and/or chain length of the first chain 115A corresponds to the first operation parameter and the direction and/or speed of movement and/or chain length of the second chain 115B corresponds to the second operation parameter. In another example, the controller electronic processor 310 receives the respective positions of the first hoist device 110A and the second hoist device 110B and the desired end position of the workpiece as the user input and determines the direction and/or speed of movement and/or chain length of the first chain 115A of the first hoist device 110A and the direction and/or speed of movement and/or chain length of the second chain 115B of the second hoist device 110B. In this example, the controller electronic processor 310 may also use the respective chain lengths of the first chain 115A and the second chain 115B from the first hoist device 110A and the second hoist device 110B for determining the first operation parameter and the second operation parameter. For example, the controller electronic processor 310 may determine the initial position of the workpiece based on the positions of the hoist devices 110 (which may be entered in a set up stage) and the respective chain lengths (which may be determined using the respective sensors 260). The controller electronic processor 310 finds the distance and direction between the initial position determined above and the desired end position received from the user input. The positions of the hoist devices 110 and the initial positions of the workpiece may, for example, be provided or determined with respect to a common reference point (e.g., a point on the floor) or multiple reference points with known relative positions. The controller electronic processor 310 uses the distance and direction to calculate the direction and/or speed of movement and/or chain length of the first chain 115A and the second chain 115B. For example, the positions may be expressed one of various formats, such as using the Cartesian coordinate system or another coordinate system. Then, for example, the direction and chain length for each hoist device 110 to move a workpiece from an initial position to an end position may be calculated by determining differences between the coordinates of the initial and end positions with respect to the positions of the hoist devices 110.
The method 700 includes providing, wirelessly using the controller electronic processor 310, a first control signal indicative of the first operation parameter to the first hoist device 110A (at block 730). The controller electronic processor 310 provides the control signals that correspond to the first operation parameter via the controller transceiver 330 to the first hoist device 110A. The first hoist device 110A receives the first control signal over the hoist transceiver 230 (that is, the first wireless transceiver). The first hoist device 110A operates based on the first control signal. That is, the first hoist device 110A controls the hoist motor 250 (that is, the first motor) of the first hoist device 110A based on the first control signal. For example, the hoist electronic processor 210 of the first hoist device 110A controls the hoist motor 250 of the first hoist device 110A to match the direction, chain length, and/or speed indicated by the first control signal.
The method 700 also includes providing, wirelessly using the controller electronic processor 310, a second control signal indicative of the second operation parameter to the second hoist device 110B (at block 740). The controller electronic processor 310 provides the control signals that correspond to the second operation parameter via the controller transceiver 330 to the second hoist device 110B. The second hoist device 110B receives the second control signal over the hoist transceiver 230 (that is, the second wireless transceiver). The second hoist device 110B operates based on the second control signal. That is, the second hoist device 110B controls the hoist motor 250 (that is, the second motor) of the second hoist device 110B based on the second control signal. For example, the hoist electronic processor 210 of the second hoist device 110B controls the hoist motor 250 of the second hoist device 110B to match the direction, chain length, and/or speed indicated by the second control signal.
In some embodiments, the method 700 may include determining the first operation parameter based on the user input rather than both the first operation parameter and the second operation parameter at block 720. This embodiment may be applicable in, for example, situations where the first hoist device 110A and the second hoist device 110B include similar operation to move the workpiece as shown in
In some embodiments, the user may provide signals continuously until the workpiece 130 reaches the desired end position. For example, the user may move the joystick controller until the workpiece 130 reaches the desired end position. In these embodiment, the method 700 repeats to continuously provide the first control signal and the second control signal (which may vary over time) to the first hoist device 110A and the second hoist device 110B until the user terminates providing the user input (e.g., releases the joystick). In some embodiments, the user may provide the desired end position along with other inputs and the method 700 may continuously provide the first control signal and the second controls signal until the desired end position is reached. Alternatively, the method 700 may provide the first control signal and the second control signal once to the first hoist device 110A and the second hoist device 110B and the first hoist device 110A and the second hoist device 110B operate until the workpiece 130 is at the desired location.
As shown in
The method 1000 further includes connecting the first hoist device 110A to the workpiece 130 (at block 1030) and connecting the second hoist device 110B to the workpiece 130 (at block 1040). The user may connect the first hoist device 110A and the second hoist device 110B to the workpiece 130 using the second hooks of the first hoist device 110A and the second hoist device 110B respectively.
The method 1000 includes calculating, using the controller electronic processor 310, a workpiece position based on the first position, the second position, and chain length information (at block 1050). As discussed above, the controller electronic processor 310 receives the first position information and the second position information from the user through the user interface 340. Additionally, the hoist controller 120 communicates with the first hoist device 110A to determine the released chain length of the first chain 115A (determined by the first hoist device 100A based on sensors 260) and communicates with the second hoist device 110B to determine the released chain length of the second chain 115B (determined by the first hoist device 100A based on sensors 260). The controller electronic processor 310 determines the workpiece position based on the position information of the hoist devices 110 and the respective chain lengths.
The method 1000 also includes receiving, using the controller electronic processor 310, a desired workpiece location (at block 1060). The user may enter the desired workpiece location using the user interface 340. For example, the location may be specified using the same coordinate system used to specify the first and second hoist positions. Based on the workpiece position and the desired workpiece location, the hoist controller 120 may automatically provide control signals to the first hoist device 110A and the second hoist device 110B (at block 1070).
The control of the first hoist device 110A and the second hoist device 110B based on the first control signal and the second control signal is further explained with respect to
Similarly, the second hoist device 110B includes a proportional-integral-derivative (PID) controller 1140, for example, implemented by the hoist electronic processor 210 of the second hoist device 110B. The PID controller 1140 or the hoist electronic processor 210 forms the motor drive of the second hoist device 110B. The PID controller 1140 is coupled to a length/speed sensor 1150 (for example, a sensor for detecting chain length). The PID controller 1140 receives sensor data from the length/speed sensor 1150. For example, the PID controller 1140 receives chain length information from the length/speed sensor 1150 indicating the amount of chain released from the second hoist device 110B. The PID controller 1140 also receives the second control signal from the hoist controller 120. The PID controller 1140 controls the motor 1160 (for example, the motor 250 of the second hoist device 110B) based on the second control signal and the chain length information to install the workpiece 130.
The method 1500 includes determining, using the controller electronic processor 310, a first operation parameter based on the user input (at block 1520). The first operation parameter may correspond to the operation of the first hoist device 110A and/or the second hoist device 110B. The controller electronic processor 310 receives the user input, for example, the desired movement of the workpiece, the desired angle of the level 1200, the positions of the hoist devices 110 and the workpiece, and determines the operation parameters of the first hoist device 110A and/or the second hoist device 110B based on the user input. For example, the controller electronic processor 310 receives a desired movement of the workpiece as the user input and determines a direction and/or speed of movement and/or chain length of the first chain 115A of the first hoist device 110A and the second chain 115B of the second hoist device 110B. The direction and/or speed of movement and/or chain length of the first chain 115A and the second chain 115B corresponds to the first operation parameter. In another example, the controller electronic processor 310 receives the respective positions of the first hoist device 110A and the second hoist device 110B and the desired end position of the workpiece as the user input and determines the direction and/or speed of movement and/or chain length of the first chain 115A of the first hoist device 110A and/or the second chain 115B of the second hoist device 110B. In this example, the controller electronic processor 310 may also use the respective chain lengths of the first chain 115A and the second chain 115B from the first hoist device 110A and the second hoist device 110B for determining the first operation parameter. For example, the controller electronic processor 310 may determine the initial position of the workpiece based on the positions of the hoist devices 110 and the respective chain lengths. The controller electronic processor 310 finds the distance and direction between the initial position determined above and the desired end position received from the user input. The controller electronic processor 310 uses the distance and direction to calculate the direction and/or speed of movement and/or chain length of the first chain 115A and the second chain 115B.
The method 1500 includes receiving, from the level sensor 1200, the level signal (at block 1530). As described above, the level sensor 1200 measures an angle of the level sensor against the gravitational pull and continuously provides the measured angle to the hoist controller 120. The method 1500 includes providing, wirelessly using the controller electronic processor 310, a first control signal indicative of the first operation parameter and the level signal to the first hoist device 110A (at block 1540). The controller electronic processor 310 provides the control signals that correspond to the first operation parameter and the level signal via the controller transceiver 330 to the first hoist device 110A. The first hoist device 110A receives the first control signal over the hoist transceiver 230 (that is, the first wireless transceiver). The first hoist device 110A operates based on the first control signal. That is, the first hoist device 110A controls the hoist motor 250 (that is, the first motor) of the first hoist device 110A based on the first control signal. For example, the hoist electronic processor 210 of the first hoist device 110A controls the hoist motor 250 of the first hoist device 110A to match the direction, chain length, and/or speed indicated by the first control signal. The first control signal may take into account the desired level angle provided by the user through the user input and indicate the direction, chain length, and/or speed such that the user desired level angle is maintained during the operation. The method 1500 may repeat until the workpiece 130 is installed at the desired location. Additionally, in some embodiments, in addition to providing a first control signal indicative of the first operation parameter and level signal to the first hoist device, in block 1540, the controller 120 may provide a second control signal indicative of a second operation parameter and level signal to the second hoist device 110B using similar principals of operation.
The method 1900 includes determining, using the controller electronic processor 310, a first operation parameter based on the user input (at block 1920). The first operation parameter may correspond to the operation of the first hoist device 110A. The controller electronic processor 310 receives the user input, for example, the desired movement of the workpiece, the desired angle of the level 1200, the positions of the hoist devices 110 and the workpiece, and determines the operation parameter of the first hoist device 110A based on the user input. For example, the controller electronic processor 310 receives a desired movement of the workpiece as the user input and determines a direction and/or speed of movement and/or chain length of the first chain 115A of the first hoist device 110A. The direction and/or speed of movement and/or chain length of the first chain 115A corresponds to the first operation parameter. In another example, the controller electronic processor 310 receives the respective positions of the first hoist device 110A and the second hoist device 110B and the desired end position of the workpiece as the user input and determines the direction and/or speed of movement and/or chain length of the first chain 115A of the first hoist device 110A and/or the second chain 115B of the second hoist device 110B. In this example, the controller electronic processor 310 may also use the respective chain lengths of the first chain 115A and the second chain 115B from the first hoist device 110A and the second hoist device 110B for determining the first operation parameter. For example, the controller electronic processor 310 may determine the initial position of the workpiece based on the positions of the hoist devices 110 (e.g., received in a set up stage) and the respective chain lengths (determined by respective sensors 260 of the hoist devices 110). The controller electronic processor 310 finds the distance and direction between the initial position determined above and the desired end position received from the user input. The controller electronic processor 310 uses the distance and direction to calculate the direction and/or speed of movement and/or chain length of the first chain 115A.
The method 1900 includes providing, wirelessly using the controller electronic processor 310, a first control signal indicative of the first operation parameter to the first hoist device 110A (at block 1930). The controller electronic processor 310 provides the control signals that correspond to the first operation parameter via the controller transceiver 330 to the first hoist device 110A. The first hoist device 110A receives the first control signal over the hoist transceiver 230 (that is, the first wireless transceiver). The first hoist device 110A operates based on the first control signal. That is, the first hoist device 110A controls the hoist motor 250 (that is, the first motor) of the first hoist device 110A based on the first control signal. For example, the hoist electronic processor 210 of the first hoist device 110A controls the hoist motor 250 of the first hoist device 110A to match the direction, chain length, and/or speed indicated by the first control signal.
The method 1900 also includes providing, wirelessly using the first hoist device 110A, a second control signal to the second hoist device 110B (at block 1940). The hoist electronic processor 210 provides the second control signal based on the first control signal via the hoist transceiver 230 to the first hoist device 110A to the second hoist device 110B. The second hoist device 110B receives the second control signal over the hoist transceiver 230 (that is, the second wireless transceiver). The first hoist device 110A determines, for example, a second operation parameter as described in the method 700 that corresponds to the operation of the second hoist device 110 based on the first control signal received from the hoist controller 120. The second hoist device 110B operates based on the second control signal. That is, the second hoist device 110B controls the hoist motor 250 (that is, the second motor) of the second hoist device 110B based on the second control signal. For example, the hoist electronic processor 210 of the second hoist device 110B controls the hoist motor 250 of the second hoist device 110B to match the direction, chain length, and/or speed indicated by the second control signal.
As shown in the control diagram of
The first hoist device 110A also provides, using the hoist electronic processor 210A, a speed of the first hoist device 110A to the second hoist device 110B. The first hoist device 110A communicates with the second hoist device 110B over the second wireless communication channel 810B to provide the speed information to the second hoist device 110B. The PID controller 1140 of the second hoist device 110B receives the speed information from the first hoist device 110A and the chain length and/or motor speed information from the length/speed sensor 1150 (for example, one or more hoist sensors 260 of the second hoist device 110B) and controls the motor 1160 (for example, the motor 250 of the second hoist device 110B) based on the speed signals and the sensor signals to install the workpiece 130. In some embodiments, if the speed or acceleration exceeds a predetermined maximum value, the hoist controller 120 may stop operation of the hoist device. Examples of the predetermined threshold may be 20% above a normal operating value. However, threshold values of more than 20% or less than 20% are also contemplated.
While some of the embodiments are described herein with respect to a single (first) hoist device 110 or with respect to a first and second hoist device 110, in some embodiments, two, three, or more hoist devices 110 are included. For example, the wireless hoist system 100 may include a third hoist device 110. Continuing the method 700, the controller electronic processor 310 also determines a third operation parameter based on the user input (at block 720), and the method 700 further includes providing a third control signal indicative of the third operation parameter to the third hoist device 110. Turning to the method 1900, with a third hoist device, an additional block may be included (e.g., after block 1940) in which a third control signal is provided to the third hoist device using the first (or second) hoist device 110. The third hoist device 110 operates based on the third control signal. In these embodiments, the hoist controller 120 communicates with the first hoist device 110A over a first wireless channel 810, the first hoist device 110A communicates with the second hoist device 110B over a second wireless channel 810B (as previously described), and the first hoist device 110A (or the second hoist device 110B) communicates with the third hoist device 110 over a third wireless communication channel 810C. As another example, the method 1500 may also operate with a third hoist device 110, in which the third hoist device 110 operates with the first and second hoist devices 110 and level 1400 similar to the manner in which the second hoist device 110 is described as operating with the first hoist device 110 and level 1400.
The housing 2010 may be an elongated tubular housing that includes grip portion 2012 and a top portion 2014. The variable speed trigger 2020 is provided on the top portion 2014 just above the grip portion 2012. The direction control pushbuttons 2030 are provided on top of the top portion 2014. The grip portion 2012 and the top portion 2014 are arranged and sized such that a user holding the handheld remote controller 2000 using the grip portion 2012 may use the index finger to pull or release the variable speed trigger 2020 and may use the thumb to push the direction control pushbuttons 2030 provided on the top portion 2014. Accordingly, the handheld remote controller 2000 is designed for single-handed user operation.
The variable speed trigger 2020 is used to control a speed of operation of the hoist devices 110. Particularly, the speed of the hoist devices varies from zero to a maximum speed, where the maximum speed corresponds to a maximum pulling amount of the variable speed trigger 2020. The speed of the hoist devices 110 is therefore controlled by varying the pulling amount of the variable speed trigger 2020. The variable speed trigger 2020 includes a body with a spring biased member such that the user can pull the variable speed trigger 2020 from an original position by asserting pressure on the variable speed trigger 2020 and the trigger 2020 returns to the original position when the user releases the variable speed trigger 2020. In some embodiments, a sense pad and wiper are provided in the handheld remote controller 2000 to determine a pulling amount of the variable speed trigger 2020. The wiper is attached to the variable speed trigger 2020 such that the wiper moves with the variable speed trigger 2020 on the sense pad. The resistance of the sense pad changes based on the position of the wiper on the sense pad. This resistance of the sense pad is detected by the controller electronic processor 310 to determine the pulling amount of the trigger. In other embodiments, a Hall-sensor design or an optical sensor design may be used to determine the pulling amount of the variable speed trigger 2020.
In some embodiments, the variable speed trigger 2020 is configured to prevent a “lock on” condition, such as where the trigger becomes stuck in a position, resulting in a user being unable to disengage a previously commanded operation. In some examples, the variable speed trigger (or other inputs on the remote controller 2000) may be contaminated by debris, tolerance, or misuse. In some embodiment, rubber boots or other protective coverings may be added to the variable speed trigger 2020 or other inputs on the remote controller 2000, which can provide protection from contaminants, as well as mechanical wear.
The remote controller 2000 may further include one or more devices to reduce accidental operation of the remote controller 2000. These devices may include kill switches, trigger/actuator guards, and double and/or triple activation triggers/switches/hand sensors. Double/triple activation triggers/switches/hand sensors are configured to require multiple operations by a user to generate a command. For example, a user may have to depress a grip sensor on the remote controller 2000 as well as depress the variable speed trigger 2020 to effectuate the desired output. Example grip sensors may include capacitive sensors, pressure sensors, etc. In other embodiments, an accelerometer may be used to detect a motion in conjunction with an operation of an input, such as via the variable speed trigger 2020, which can be used as an additional input.
The remote controller 2000 may further include safety inputs such as a kill switch or emergency stop button to stop all movement of the hoist device 110. In one embodiment, the remote controller 2000 (and/or the hoist device) may include microphone or other audio input configured to recognize a vocal command or indicator related to stopping operation of the hoist device 110. For example, the audio input may be configured to recognize a yell/raised voice/loud noise and stop the operation of the hoist device. In some examples, environmental sounds, such as transient noises, scraping noises, or other sounds indicating undesired operation and or potential interference with the load may also be determined via the audio input. In one embodiment, a controller of the remote controller 2000 (such as described below) may be configured to process the audio input. In other embodiments, the hoist controller 120 is configured to process the audio input. In one embodiment, additional safety sensors, such as pinch sensors, may be placed onto the workpiece 130 which can output a signal to the remote controller 2000 and/or hoist controller 120. For example, a person guiding the workpiece into position may activate the pinch sensor by applying a force in order to stop movement of the hoist system 100. In other examples, the pinch sensor may be actuated if the workpiece 130 comes into contact with an object, and thereby stops operation of the hoist device 110.
The direction control pushbuttons 2030 are used to control a direction of operation of the hoist devices 110. The direction control pushbuttons 2030 include an up direction pushbutton 2030A and a down direction push button 2030B. The user may press down on one of the direction control pushbuttons 2030 to select a direction of operation of the hoist devices 110. In one embodiments, a user may be required to keep one of the direction control pushbuttons 2030 to be pressed down for the duration of operation of the hoist device 110. For example, the user may be required to actuate both a direction control pushbutton 2030 and the variable speed trigger 2020 to operate the hoist device 110. In this embodiments, the release of either the direction control pushbutton 2030 or the variable speed trigger 2020 may stop the operation of the hoist devices 110. In other embodiments, the user may press the direction control pushbutton 2030 at the start of the operation and the hoist devices 110 are operated in the selected direction without needing continuous actuation of the direction control pushbutton 2030.
In one embodiment, the hoist controller 120 is configured to receive commands from the remote controller 2000. The hoist controller 120 may be configured with one or more safety interlocks to prevent undesired operation of the hoist device. For example, the hoist controller may be configured to monitor one or more electronic signals from the remote controller 2000 and verify that the electronic signals (e.g. commands) are valid and within specification. In some embodiments, in response to determining that the electronic signals are not valid, the hoist controller 120 does not execute the requested command associated with the received signal. Where the hoist controller 120 is executing a command (e.g. moving a load up or down, etc.) and receives a subsequent electronic signal from the remote controller 2000 that is determined to be invalid, the hoist controller 120 stops the current operation and waits for a further valid electronic signal from the remote controller 2000 that is determined to be valid. Similarly, in some examples, the remote controller 2000 is configured to transmit redundant signals for all commands input by a user. The hoist controller 120 may be configured to monitor for the redundant command signals from the remote controller 2000, and stop a current operation and/or prevent the commanded operation where the redundant signals are not valid. The hoist controller 120 may determine that redundant commands are invalid based on receiving only one of the two redundant signals and/or receiving different commands for each of the redundant commands.
In other examples, the hoist controller 120 is configured to provide one or more safety interlocks related to commands received from a remote source, such as remote controller 2000. For example, when a command has been received by the hoist controller (such as UP or DOWN), the hoist controller will perform that operation only for as long as the command is issued. For example, if the hoist controller 120 receives an UP command the hoist controller 120 commands the hoist to raise the load up. If an issue is encountered, such as a mechanical issue, loss of power, loss of communication with remote controller 2000, etc., the hoist controller 120 will stop the operation. However, as the last valid received command was an UP command, the hoist controller will prevent the load from being lowered (e.g. a DOWN operation). Similarly, if the last command received was a DOWN command, the hoist controller 120 will either operate the hoist device 110 in a DOWN mode, or stop operation in the event of an issue, but will not allow for an UP operation to be executed until a valid UP command is received.
The communication channel pushbutton matrix 2040 may include a plurality of communication channel pushbuttons each corresponding to one communication channel of the handheld remote controller 2000. Each communication channel may be programmed to communicate with a single hoist device 110. In the example illustrated, the communication channel pushbutton matrix includes four communication channel pushbuttons to communicate with four separate hoist devices 110 (individually identified as 110A-D). The user may select one or more hoist devices 110 for control by the handheld remote controller 2000 by pressing the corresponding communication channel pushbutton. In the example illustrated, the user selected a first communication channel pushbutton 2040A and a second communication channel pushbutton 2040B for simultaneous control of a first hoist device 110A and a second hoist device 110B corresponding to the first communication channel pushbutton 2040A and the second communication channel pushbutton 2040B. Each communication channel pushbutton may also including a light indicator (e.g., an LED) to illuminate to indicate that the communication channel pushbutton is selected. In one embodiment, a communication channel pushbutton illuminates to indicate that the communication channel pushbutton is selected and is not illuminated when the communication channel pushbutton is not selected. In another embodiments, a communication channel pushbutton is illuminated in a first color (e.g., green) to indicate the communication channel pushbutton is selected and is illuminated in a second color (e.g., red) different that the first color to indicate that the communication channel pushbutton is not selected.
The controller transceiver 330 is, for example, a Bluetooth® chip, a radio-frequency (RF) transceiver chip, and the like. The controller transceiver 330 includes an antenna 335 for transmitting and receiving signals from the hoist devices 110. The controller transceiver 330 is coupled to the controller electronic processor 310 to receive control signals from the controller electronic processor 310 for transmission and for providing signals from the hoist devices 110 to the controller electronic processor 310.
The variable speed trigger 2020 is coupled to the controller electronic processor 310 to provide speed control signals to the controller electronic processor 310. As described above, the variable speed trigger 2020 provided an indication of the amount to which the variable speed trigger 2020 is pulled to the controller electronic processor. The direction control pushbuttons 2030 are coupled to the controller electronic processor 310 to provide actuation signals to the controller electronic processor 310.
For example, the first direction control pushbutton 2030A provides a signal when the first direction control pushbutton 2030A is pressed and does not provide any signal when the first direction control pushbutton is not pressed. The first direction control pushbutton 2030A may continue to provide the signal as long as the first direction control pushbutton 2030A remains pressed. In one example, when the first direction control pushbutton 2030A is pressed, the first direction control pushbutton 2030A closes a circuit forming a current path from the controller electronic processor 310 to ground and drawing a current from the controller electronic processor 310. When the controller electronic processor 310 detects that a current is being drawn from the port connected to the first direction control pushbutton 2030A, the controller electronic processor 310 determines that the first direction control pushbutton 2030A is pressed. When the first direction control pushbutton 2030A is released, the circuit is opened terminating the current draw from the controller electronic processor 310.
Similarly, the second direction control pushbutton 2030B provides a signal when the second direction control pushbutton 2030B is pressed and does not provide any signal when the second direction control pushbutton is not pressed. The second direction control pushbutton 2030B may continue to provide the signal as long as the second direction control pushbutton 2030B remains pressed. In one example, when the second direction control pushbutton 2030B is pressed, the first direction control pushbutton 2030B closes a circuit forming a current path from the controller electronic processor 310 to ground and drawing a current from the controller electronic processor 310. When the controller electronic processor 310 detects that a current is being drawn from the port connected to the first direction control pushbutton 2030B, the controller electronic processor 310 determines that the first direction control pushbutton 2030A is pressed. When the second direction control pushbutton 2030B is released, the circuit is opened terminating the current draw from the controller electronic processor 310. In the example illustrated, the first direction control pushbutton 2030A corresponds to UP and the second direction control pushbutton 2030B corresponds to DOWN.
The communication channel pushbutton matrix 2040 is coupled to the controller electronic processor 310 to provide control signals to the controller electronic processor 310. The communication channel pushbutton matrix 2040 includes four communication channel pushbuttons 2040A, 2040B, 2040C, 2040D. The communication channel pushbuttons operate similar as the direction control pushbuttons 2030A as described above. However, at least in some embodiments, the communication channel pushbuttons are toggle switches such that the communication channel pushbuttons can be pressed once to turn a communication channel on and once to turn the communication channel off. That is, the communication channel pushbuttons need not be pressed continuously.
The communication channel pushbutton matrix 2040 also includes a plurality of indicators 2045A, 2045B, 2045C, 2045D corresponding to the four communication channel pushbuttons. The plurality of indicators receive control signals from the controller electronic processor 310. In some embodiments, an indicator is illuminated or its color is changed (e.g., red to green) when a corresponding one of the communication channel pushbutton is activated.
The hoist transceiver 230 is, for example, a Bluetooth® chip, a radio-frequency (RF) transceiver chip, and the like. The hoist transceiver 230 includes an antenna 235 for transmitting and receiving signals from the handheld remote controller 2000. The hoist transceiver 230 is coupled to the hoist electronic processor 210 to receive signals from the hoist electronic processor 210 for transmission and for providing control signals from the handheld remote controller 2000 to the hoist electronic processor 210.
Referring back to
In some embodiments, rather than being hardcoded, each communication channel pushbutton may be paired on-the-fly with a hoist device 110. The pairing operation may be performed similar to Bluetooth® pairing or other RF communication protocol pairing. This allows for additional flexibility in the system by allowing a user to use the same handheld remote controller 2000 with several hoist devices 110. Additionally, a lost or broken handheld remote controller 2000 may be easily replaced by pairing a new handheld remote controller 2000 with the hoist devices 110.
In some embodiments, each hoist devices 110 may be paired with only one handheld remote controller 2000 at a time. For example, each hoist device may be store only one active address of a handheld remote controller 2000 at a time. Accordingly, the hoist device 110 can avoid receiving multiple control signals or conflicting control signals from different handheld remote controllers 2000 at the same time.
In some embodiments, each indicator 2045 associated with communication channel pushbutton may illuminate in a different color (e.g., one of red, blue, yellow, and green). The hoist device 110 may include similar indicators 2050 on the device. Referring to
In some embodiments, the controller transceiver 330 may be configured to transmit on unique frequencies that are not associated with other devices within a certain range of the hoist device 110. In one embodiment, the controller transceiver 330 is configured to listen for other signal operating at or near the operating frequency of the remote controller 2000 and/or hoist devices 110, and perform an action if a potential interfering signal is detected. In one embodiment, the controller transceiver 330 may stop operation and generate an alert to a user indicating that the operating frequency is in use by other devices. The user may then change the operating frequency of the controller transceiver 330, or the user may disable the interfering device (or modify the operating frequency thereof). In other embodiments, the controller transceiver may automatically switch to a different frequency that is different from the interfering frequency. For example, the controller transceiver 330 may use frequency hopping whenever interference is detected. Further the controller transceiver 330 may also control the other wireless transceivers associated with the hoist devices 110 to switch frequencies accordingly.
In one embodiment, the controller transceiver 330 is configured to pair with the one or more hoist devices 110 using an encrypted communication protocol to prevent other devices from interfering with the communications between the remote controller 2000 and the hoist devices 110. Additionally, as described above, the hoist controller 120 may perform redundant checks of the commands received from the remote controller 2000 to ensure the commands are valid. In other examples, the controller transceiver 330 is configured to send multiple signals (either redundant or dissimilar), which are checked by the by the hoist controller 120 for accuracy and verification before executing the command.
In other examples, the controller transceiver 330 and/or the hoist controller 120 performs time based signal quality and/or accuracy checks of all received signals. The time based signal checks evaluate signals over a period of time to verify that the signals are acceptable and verifiable. This can aid in discriminating between noise and actual signals. In other embodiments, the receiving device (i.e. the controller transceiver 330 and/or the hoist controller 120) may evaluate a strength of the received signal, and only execute a command associated with the received signal based on the signal strength being above as signal strength threshold. In one embodiment, the controller transceiver 330 and/or the hoist controller 120 may use received signal strength-based location determination algorithms (RSSI) and will only execute commands with the associated received signals are within a threshold distance. In a further embodiment, the controller transceiver 330 may be configured to only interface with the hoist controller 120 via line of sight communications, such as infrared (IR) or other line of sight communication protocols.
Referring to
In some embodiments, a smart telephone may also be used in place of or in addition to the handheld remote controller 2000.
Referring to
Referring to
Referring to
Accordingly, at least in some embodiments, the first trigger 2020A provides more variation in speed for each successive amount of pulling and has a larger range of control (e.g., 0-100% duty cycle), while the second trigger 2020B provides less variation in speed for each successive amount of pulling and has a lower range of control (e.g., 0-10% duty ratio). In some embodiments, the first trigger 2020A may be used for larger movements (for example, larger distances) of a workpiece 130 and the second trigger 2020B is used for finer movement (for example, small distances) of the workpiece 130. In another embodiment, the first trigger 2020A and the second trigger 2020B are not used concurrently and, rather, for example, one trigger signal is ignored when the other is already activated.
In some embodiments, rather than varying motor speed based on an amount of depression of a trigger of the remote controller 120 or 2000, the speed dial 2520 or another speed selector input button or slider may be used to set certain speeds (for example, low, medium, and high speeds) of the hoist motor 250. In some embodiments, a smart telephone may be used to program the speed dial 2520 to certain speeds. These set speeds may be used as desired speeds in a closed-loop control function implemented by the hoist electronic processor 210 such that the set speeds are held substantially constant. In other words, the hoist electronic processor 210 measures speed of the motor 250, compares to the desired speed, and adjusts current flow to the motor (e.g., by adjusting a PWM duty cycle driving the motor) to maintain the speed of the motor 250 at the desired speed. In other embodiments, an open loop control function is implemented by the hoist electronic processor 210 such that the desire speed maps to a particular current flow to the motor 250 (e.g., a particular PWM duty cycle), which is then used to drive the motor 250.
In some embodiments, the hoist device 110 may be provided with a worklight to illuminate a working surface, a workpiece 130, or an area in which a workpiece 130 is being moved. For example, the worklight may direct light toward the workpiece, as well as the surrounding area. The hoist device 110 may also include indicators to provide visible notifications and/or a speaker to provide audible notifications (for example, beeps, alarms, voice notifications, and the like to a user). The indicators and speaker may be used in conjunction with other techniques and methods described herein to provide the different notifications, alarms, or indications.
In some embodiments, the hoist system 100 may impose a distance limitation on the hoist devices 110 and the controller 120. Particularly, to ensure that signals may be accurately received by the hoist devices 110, the hoist system 100 may prevent operation of the hoist devices 110 when the distance between the controller 120 and the hoist device 110 is more than a predetermined amount. The controller 120 may determine the distance between the controller 120 and the hoist device 110 using a propagation delay of a roundtrip signal from the controller 120 to the hoist device.
The method 2600 also includes transmitting, using the controller 120, a timing signal including a first time to the hoist device 110 (at block 2620). The controller 120 may record the first time and embed the first time into the timing signal, for example, by time stamping the timing signal. The first time corresponds to the time at which the timing signal is transmitted from the controller 120.
The method 2600 includes receiving, at the hoist device 110, the timing signal at a second time from the controller 120 (at block 2630). The hoist device 110 may record the time at which the timing signal was received by the hoist device 110. The method 2600 further includes determining, using the hoist electronic processor 210, the distance between the controller 120 and the hoist device 110 based on the first time and the second time (at block 2640). In one example, the hoist electronic processor 210 determines the distance by calculating the propagation time and multiplying the propagation time with a known speed of transmission (that is, speed of light). The hoist electronic processor 210 calculates the propagation time by subtracting the first time from the second time. In some embodiments, the hoist electronic processor 210 may adjust the propagation time to account for processing delays by the controller 120 and/or the hoist device 110.
The method 2600 includes determining, using the hoist electronic processor 210, whether the distance between the controller 120 and the hoist device 110 is below a predetermined threshold (at block 2650). The hoist electronic processor 210 compares the distance between the controller 120 and the hoist device 110 to the predetermined amount. When the distance between the controller 120 and the hoist device 110 is below the predetermined threshold, the method 2600 includes allowing the controller 120 to control operation of the hoist device 110 (at block 2660). When the distance between the controller 120 and the hoist device 110 is above the predetermined threshold, the method 2600 includes performing a predetermined action (at block 2670). The predetermined action may include providing an indication on the hoist device 110 and/or providing an indication on the controller 120. The indication informs the user that the controller 120 is not within an operating distance of the hoist device. The predetermined action may also include preventing the controller 120 from operating the hoist device 110. For example, the hoist device 110 may ignore commands from the controller 120 until the method 2600 is executed again and the distance is determined to be below the predetermined threshold.
In some embodiments, the controller 120 and the hoist devices 110 use a Bluetooth® communication protocol to exchange control and other signals. In other embodiments, the handheld remote controller 2000 and the hoist devices 110 may use a proprietary radio-frequency (RF) communication protocol to exchange control and other signals.
In some embodiments, rather than individually communicating with each hoist device 110, the controller 120 may communicate with a single hoist device 110, which in turn communicates with other hoist devices 110. For example, as shown in
In some embodiments, two or more hoist devices 110 may be tethered together for concurrent operation. Tethering may be performed on a user interface of the hoist devices 110 and/or on the user interface of the handheld remote controller 2000. In some embodiments, tethering may also be performed on a connected smart telephone device running an application designed to function with the hoist device system described herein. When two or more hoist devices 110 are tethered together, the hoist devices 110 may exchange operation and control signals to work in unison to perform a task.
In the example illustrated in
The method 2900 includes determining a corresponding first speed level for a first hoist device 110A based on a load on the first hoist device 110A and a load on the second hoist device 110B (at block 2920). The method 2900 also includes determining a corresponding second speed level for a second hoist device 110B based on the load on the first hoist device 110A and the load on the second hoist device 110B (at block 2930). The first speed level and the second speed level are selected to maintain the starting load profile on each of the hoist devices 110 throughout the lifting process. Accordingly, the ratio between the first speed level and the second speed level is inversely proportional to the ratio between the load on the first hoist device 110A and the load on the second hoist device 110B.
The method 2900 includes operating the first hoist device 110A at the first speed level (at block 2940) and operating the second hoist device 110B at the second speed level (at block 2950). The method 2900 maintains the first speed level and the second speed level as long as the load on the first hoist device 110A and the load on the second hoist device 110B are consistent with the starting profile (e.g., within a predetermined percentage or other threshold of the starting profile).
The method 2900 includes determining whether the load on the first hoist device 110A is different from the starting profile (at block 2960) and determining whether the load on the second hoist device 110B is different from the starting profile (2970). When the load on the first hoist device 110A and the load on the second hoist device 110B are consistent with the starting profile (e.g., within a predetermined percentage or other threshold of the starting profile), the method 2900 returns to blocks 2940 and 2950 to maintain current operation.
When the load on the first hoist device 110A and/or the load on the second hoist device 110B are inconsistent with the starting profile (e.g., the load is outside of a predetermined percentage or other threshold of the starting profile), the method 2900 includes operating the first hoist device 110A and the second hoist device 110B to return to the starting profile (at block 2980). For example, the method 2900 may halt operation, then then may operate one or both of the first hoist device 110A and the second hoist device 110B to return to the starting profile. Once returned to the starting profile, the method 2900 returns to blocks 2920 and 2930 to continue operation. In some embodiments, rather than returning to starting profile, the method 2900 may include determining new speed levels based on the new load profile and operating the hoist devices 110 based on the new speed levels. For example, if the first hoist device 110A detects an increased load (which should correspond to the second hoist device 110B detecting a decreased load), in block 2980, the first hoist device 110A may be controlled to increase its speed and/or the second hoist device 110B may be controlled to decrease its speed to shift more of the load to the second hoist device 110B and return to the starting profile. Similarly, if the first hoist device 110A detects an decreased load (which should correspond to the second hoist device 110B detecting an increased load), in block 2980, the first hoist device 110A may be controlled to decrease its speed and/or the second hoist device 110B may be controlled to increase its speed to shift more of the load to the first hoist device 110A and return to the starting profile.
In some embodiments, the two paths between recording the starting profile block 2910 and the operating to return to the starting profile block 2980 (i.e., the path with blocks 2920, 2940, and 2960 and the path with blocks 2930, 2950, and 2970) may be executed in parallel so each of the first hoist device 110A and the second hoist device 110B may be continually adjusting motor speed to maintain the starting profile.
The tilt winch 3000 include two rope openings 3030 provided on each side of a housing 3040 of the tilt winch 3000. The rope openings 3030 provide an outlet for a rope 3050 that may be pulled in and let out by the tilt winch 3000. The tilt winch 3000 may include a motor similar to the motor of the hoist device 110 to adjust a length of the rope 3050. The rope 3050 may be tied on each side of a workpiece 130. The tilt winch 3000 is then operated (e.g., the winch motor is controlled) to adjust a length and/or tension of the rope 3050 on each side of the tilt winch 3000. In some embodiments, a third opening may be provided on the bottom of the winch housing 3040 to allow a second rope 3060 to be pulled in or let out. The second rope 3060 may be provided in addition to the rope 3050 or alternatively in lieu of the rope 3050. The length and tension in the second rope 3060 may similar be adjusted as the rope 3050 using the winch controller 3020.
Turning now to
At process block 3110, the number of lifts left in the power supply is determined by dividing the determined power left in the power source in process block 3108, by the power of a standard lift. If the number of remaining lifts is determined to be less than 2 at process block 3112, a user is alerted that only one lift remains in the power source. In some embodiments, the alert may be a visual alert provided on the remote controller 2000, described above. For example, the alert may be presented via one or more LEDs, or via a user interface, such as an LCD screen. In other embodiments, audio or tactile alerts may be provided to the user, either alone, or in combination with the above described visual alerts. If the number of lifts is not less than two, the number of remaining lifts is displayed for the user at process block 3114. For example, the remaining lifts may be displayed via a user interface of the remote controller 2000.
As an example, if the minimum voltage of the power source is 14V, the voltage drop is 0.5 VDC, the actual voltage of the power source is 16V, and the average current is 10 A, then the remaining power can be calculated as: 16V−14V*(10 A/0.5)=40 W. Then, based on the power of a standard lift being 20 W, the remaining lifts can be calculated as: 40 W/20 W=2.
Turning now to
The electronic processor then monitors a magnitude of a change in the load being lifted at process block 3204. In some embodiments, the magnitude of the load may be determined based on a load sensor output. The load sensors could monitor pressure in a hydraulic fluid, or a strain on a load bearing chain or other connection between the load and the hoist device 110. In other examples, a current of the motor 250 may be used to determine a magnitude of the load being lifted by the hoist device 110. At process block 3206, the electronic processor determines if the load magnitude has increased beyond a soft-start limit. In some embodiments, the soft-start limit is a ratio of motor acceleration to load. In response to the load magnitude increasing beyond the soft-start limit, the electronic processor reduces the acceleration of the motor 250 (e.g., by reducing the PWM duty cycle that controls driving of the motor 250) at process block 3208. In one embodiment, the electronic processor reduces the acceleration such that the acceleration is inversely proportional to the magnitude of load change, as shown in
In response to determining that the load magnitude has not increased beyond the soft-start limits, the electronic processor increases the motor acceleration (e.g., by increasing the PWM duty cycle that controls driving of the motor 250) at process block 3210. In some embodiments, the acceleration is not increased beyond a predetermined level, such as an acceleration limit specified by the predetermined soft-start ramp. The controller then resumes monitoring the magnitude of change of the load at process block 3204.
Turning now to
Turning now to
In order to determine a dynamic load value, an electronic processor, such as the hoist electronic processor 210 described above, of the hoist 3502 may compare an actual speed of the hoist motor to an expected speed. The difference between the expected speed and the actual speed is proportional to the load. In some examples, the hoist 3502 may control a motor to raise and lower the load 3504. The hoist 3502 may control the speed of the motor by varying the duty cycle of a PWM cycle. For a no-load condition, the expected speed at a given duty cycle is known by the electronic processor (e.g., from experimental testing and storing values in the hoist memory 220 at manufacture). The electronic processor may further receive a speed feedback signal from the motor 250 (e.g., from associated Hall sensors providing signals indicating motor speed). The electronic processor then can be configured to determine the difference between the expected speed (e.g. the no-load speed) and the actual speed to determine a magnitude of the load.
In other examples, motor current may be used in lieu of motor speed. For example, the electronic processor may measure a current measured when lifting load at a given PWM duty cycle. The electronic processor then correlates the measured current at the determined duty cycle to determine the magnitude of the load. In one example, the electronic processor may access a look up table to determine a load magnitude based on the measured current and determined PWM duty cycle applied to the motor. In some embodiments, the hoist 3502 may only use static measurements or dynamic measurements. However, in some embodiments, the hoist 3502 may use both static and dynamic load measurements to provide additional verification of the load magnitude.
Turning now to
The sensors in the smart hook 3600 may be configured to determine if the load is imbalanced. For example, the accelerometer and/or gyroscope of the electronics module 3604 can detect orientations or movements of the smart hook 3600 that can indicate an imbalance of the load (e.g. the smart hook is not on dead center of the load during a lift). This can be seen in
When the hoist device 110 is powered on, a magnetic flux is formed between the coil 152, the magnet body 148, and the armature 146 to compress the biasing member 156 so the armature 146 disengages with the friction disk 142. As a result, an air gap 158 is formed between the armature 146 and the friction disk 142 to allow the output shaft 124 to rotate. In some embodiments, an electromagnetic brake 122 may include an override mechanism 162 that is operably coupled to the armature 146 to allow a user to manually close the armature 146 to disengage the electromagnetic brake 122. For example, the override mechanism 162 may be a lever integrated with the electromagnetic brake assembly 122, or may be adjusted using a screw driver or other tools. Manually disengaging the electromagnetic brake 122 may allow the user to adjust the length of the chain 115 to adjust the positioning of the workpiece (
In some embodiments, a ratcheting device, such as a ratcheting socket may be coupled to manual operation mechanism 164 to allow a user to manually adjust the position of the workpiece 130 attached to the chain 115, thereby eliminating the need for a second chain or lever 182 to be permanently attached to the manual operation mechanism 164. In some embodiments, the manual operation mechanism 164 and/or the hoist motor 250 may include a fitting to allow for a user to couple a powered device or hand operated device to adjust the position of the workpiece 130 attached to the chain 115. The fitting may be various types of fittings, such as square fittings, hex fittings, 12 point drive fittings, etc. By using a powered device or a hand crank connected to the fitting, the manual operation mechanism 164 allows the load to be lowered even when power to the hoist motor 250 is removed.
As illustrated in
As illustrated in
In other embodiments, the limit switch 186 may be an electromechanical rotary limit switch to automatically stop travel when a set number of revolutions or rotational position is reached. The hoist device 110 may have a preset number of revolutions that correlate to the maximum distance the chain 115 can travel or the minimum distance the chain 115 can travel. In other embodiments, the limit switch 186 may detect the number of chain links to automatically stop the hoist device 110 when a predetermined number of chain links has been detected. In some embodiments, the hoist controller 120 or a separate device (e.g., a smart phone) is configured to communicate with the hoist device 110 to set the limits for travel of the chain 115. For example, the user may control the hoist device 110 to move the chain 115 to a desired maximum limit (whether upper or lower limit), and then press a button the user interface of the hoist controller or device, which causes transmission of a signal to the hoist device 110 to store the current chain 115 position as a limit (whether in terms of a rotational position of a rotary encoder or chain link). Then, during later operation, the hoist device 110 is configured to stop driving the motor 250 when the chain 115 reaches the limit previously set. A similar process can be used to set both the upper limit and lower limit.
In other embodiments, the limit switch 186 may include an ultrasonic pulse generator and receiver. The ultrasonic pulse generator may be configured to transmit an ultrasonic pulse along the length of chain. The ultrasonic pulse may return to the ultrasonic receiver after reaching the end of chain, and a time to return may be determined and used to determine a length of chain between the hoist device 110 and the end of the chain 115. In other embodiments, a change in frequency of the ultrasonic pulse may be used to determine the length of chain 115 remaining. In one embodiment, the limit switch 186 may be a time-of-flight (“ToF”) sensor configured to detect a time-of-flight of a signal from the hoist device 110 to the end of the chain. In one embodiment, the time of flight may be a laser or ultrasonic time-of-flight sensor. For example, a laser emitter on the hoist device 110 may configured to transmit a laser output which is received by a receiving device at the end of the chain. The ToF sensor may be configured to determine a length of the chain based on the measured time of flight of the laser signal. In other embodiments, the ToF sensor is a radio TOF sensor. The hoist device 110 may have a radio transceiver in communication with a second radio transceiver located at the end of the chain 115. Radio signals may be transmitted and received from both radio transceivers, and the associated time of flight for the signals to be received after being transmitted (or transmitted and subsequently received) may be used to determine a length of the chain 115.
In still further embodiments, the limit switch 186 may include a weight sensor to weigh the non-loaded length of the chain 115. For example, a storage device, such as a bag may hold the excess (non-loaded) chain 115. The limit switch 186 may measure the weight of the chain in the storage device and determine a length of loaded and unloaded chain 115 based on the weight.
As illustrated in
In other embodiments, as illustrated in
In some examples, other auto-stop devices may be used with the hoist device 110. In one example, the chain 115 may be painted, coated, or otherwise made to have different colors near the ends of the chain 115. A sensor, such as an imaging sensor, an infrared sensor, or other sensor within the hoist device 110 may be configured to detect the color change and stop the operation of the hoist device 110 before the end of the chain is reached. In other embodiments, the ends of the chain 115 may be sized differently (e.g. larger or smaller links), which can be detected by the hoist device 110 and subsequently cause the hoist device 110 to stop before the end of the chain is reached.
With reference to
In other embodiments, as illustrated in
With reference to
To prevent uncontrolled descending of the workpiece 130 following the motor 250 losing power (such as a battery being discharged), the hoist device 110 includes redundant and fail-safe systems to allow for the load to be safely lowered. Turning now to
Turning now to
In some embodiment, the above ratchet clutches 5200, 5250 may be coupled to one or more sprockets within the hoist device 110 that are coupled to the drive shaft. In some embodiments, the ratchet clutches 5200, 5250 may be coupled to a final sprocket in direct connection with the chain holding the load, as described above. Thus, in the event of a drive shaft malfunction (e.g. drive shaft becomes loose, etc.), the ratchet clutches 5200, 5250 engage the final sprocket to prevent movement of the load.
In some embodiments, the hoist device 110 may include a transmission, as described above, having a high enough gear reduction ratio such that the friction created by the gearing is not overcome by a load attached to the hoist. In other embodiments, the hoist device 110 may use a continuous drive train to eliminate clutches that may be susceptible to failure during operation. As shown in
As described above, it is important to ensure that when a stop command is transmitted by the remote, or other safety sensor within the hoist system, such as hoist device 110, that the hoist is stopped and the load must come to rest as quickly as possible. In some embodiments, a mechanical brake may be used to stop the operation of the hoist device 110. For example, friction brakes, ratcheting brakes (similar to those shown in
As shown in
In some examples, a braking mechanism, such as those described above, may be controlled via a remote control, such as remote control 2000. In one embodiment, the remote control 2000 may be configured to transmit multiple, redundant braking commands when a braking input is received from a user. The redundant braking commands may then be provided to a controller, such as controller 120 described above, as described above.
Turning now to
In response to determining that the measured parameters do not exceed one of the predetermined thresholds, the hoist controller 120 continues to operate the hoist device 110 at process block 5702. In response to determining that the measured parameters do exceed one of the predetermined thresholds, the operation of the hoist device is modified at process block 5706. In one example, where the force/current parameter is determined to exceed a threshold value indicating a sudden increase in load, the hoist controller 120 stops operation of the hoist device 110. In some embodiments, the hoist controller 120 stops the operation of the hoist device for a predetermined time period, such as one minute. However, predetermined time periods of more than one minute or less than one minute are also contemplated. In other embodiments, the hoist controller 120 stops operation of the hoist device until a user override is received by the hoist controller 120. Similarly, the hoist controller 120 may stop operation of the hoist device 110 in response to the force/current parameter being determined to be below a predetermined threshold. In other embodiments, the hoist controller 120 may retract the load a predetermined amount to relieve the load of a potential impact or pinch point. For example, the hoist controller 120 may control the hoist device 110 to retract the load by six inches. However, retraction distances of more than six inches or less than six inches are also contemplated. After the hoist device retracts the load by the predetermined amount, the load controller 120 may again evaluate one or more operational parameters, such as those described above, to determine whether the adverse operational condition has been resolved. If the measured operational parameters still exceed the predetermined thresholds, the hoist controller 120 may instruct the host device 110 to stop.
Turning now to
Turning now to
Turning now to
Turning now to
Turning now to
Thus, various embodiments described herein provide for a wireless hoist system. Various features and advantages are set forth in the following claims.
This application claims priority to U.S. Provisional Patent No. 62/868,297, filed Jun. 28, 2019, U.S. Provisional Patent No. 62/951,394, filed Dec. 20, 2019, and U.S. Provisional Patent No. 62/965,676, filed Jan. 24, 2020, the entire contents of all of which are incorporated by reference herein.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2020/039908 | 6/26/2020 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62965676 | Jan 2020 | US | |
| 62951394 | Dec 2019 | US | |
| 62868297 | Jun 2019 | US |
