Note: Descriptions are shown in the official language in which they were submitted.
1
MONITORING SYSTEM AND METHOD
RELATED APPLICATIONS
[0001] The present application claims priority to Canadian Ser. No. 2,974,819,
filed on July 28,
2017; U.S. Prov. App. No. 62/538,966, filed on July 31, 2017; Canadian Ser.
No. 2,983,837,
filed on October 26, 2017; U.S. App. No. 15/815,892, filed on November 17,
2017; U.S. Prov.
App. No. 62/631,059, filed on February 15, 2018; and Canadian Ser. No.
2,997,589, filed on
March 7, 2018. The contents of which are all explicitly incorporated by
reference in their
entireties.
FIELD
[0002] This invention is in the field of hoist lifting systems, and more
specifically to planning
and monitoring of components in a hoist lifting system.
BACKGROUND
[0003] Vehicles that carry loads are subject to changing forces depending on
the weight of the
load that they are carrying and the position of the load relative to the
vehicle. Additionally,
many load lifting vehicles are meant to lift the load from a resting position
on the ground or other
surface and move the suspended load to another position before placing it
down. This moving of
the load causes moments acting on the vehicle as a result of the load to
change as the load is
moved between positions. These loads seriously affect the stability of the
vehicle carrying the
load and in cases where the stability is affected enough, the vehicle can tip
as a result of the
forces applied to the vehicle by the load.
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[0004] The tipping of the vehicle can be caused by the weight of the load
being too great, the
load being unbalanced, a combination of the load being too great and extended
to far away from
the main body of the vehicle, etc. Additionally, the risk of a vehicle tipping
as a result of a load
can be increased by the vehicle being positioned on or moving across a sloped
ground surface.
While the weight of the load and its position might not be a problem if the
vehicle is provided on
a level ground surface, when the ground surface is sloped (including sloped in
more than one
direction) the slope of the ground surface can greatly affect the tipping
moments that are created
on the vehicle by the load. This can not only cause a load that would not
cause an issue on level
ground to put a vehicle in danger of tipping because of the sloped ground
surface, but it can also
greatly affect moments acting on the vehicle and the direction the moments are
acting in.
[0005] The aforementioned conditions may become particularly acute when
multiple vehicles
are used to operate together to lift a single load.
SUMMARY
[0006] The aspects as described herein in any and all combinations.
[0007] According to an aspect, there is provided a system for monitoring one
or more
components of a hoisting machine having a processing structure; and a non-
transitory computer-
readable memory storing instructions to configure the processing structure to:
receive hoist
machine data; determine a rotation speed of at least one bearing from the
hoist machine data;
determine a travel speed of a rope from the hoist machine data; determine a
load on the at least
one bearing from the hoist machine data; determine a friction in the at least
one bearing from the
hoist machine data; and store the rotation speed, the travel speed, the load,
and the friction in a
maintenance database stored within the non-transitory computer-readable
memory. The hoist
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machine data may account for changes in the at least one component during
operation of the
hoisting machine. A wear of the one or more components may be continuously
calculated,
wherein the wear comprises at least one of a bearing wear and a rope wear. The
system may
further comprise one or more sheave rotation sensors transmitting a rotation
measurement to the
processing structure.
[0008] According to another aspect, the non-transitory computer-readable
memory may further
comprise one or more instructions to configure the processing structure to:
calculate a, prediction
of a remaining life of the components; and/or direct one or more maintenance
activities
according to the maintenance database. The maintenance activities may be
selected from at least
one of: inspection of the at least one component, replacement of the at least
one component,
directing lubrication of the at least one component, and/or automatically
performing the
lubrication of at least one component. The maintenance activities may be
triggered by at least
one of: a plain bearing wear, a sheave bearing friction factor deviation,
rolling-contact bearing
load-adjusted revolutions, a structural fatigue, and/or a rope life.
[0009] According to yet another aspect, the non-transitory computer-readable
memory may
further comprise one or more instructions to configure the processing
structure to: monitor an
instantaneous state of the at least one component; output an overload warning
to at least one
display; override operation of the hoisting machine to mitigate an overload
condition; detect
winch bird-caging; detect failures of the one or more bearings; create an
incident log listing at
least one of: failures, breaches of provisions in an operating standard,
overload incidents, and
create an improvement to maintenance practices. In some aspects, the non-
transitory computer-
readable memory may further comprise one or more instructions to configure the
processing
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structure to: calculate an instantaneous load applied to a first sheave set
axle and a second sheave
set axle.
[0010] According to another aspect, the system may further comprising one or
more force
sensors measuring the instantaneous load applied to at least one of the first
sheave set axle and
the second sheave set axle. The non-transitory computer-readable memory may
further comprise
one or more instructions to configure the processing structure to: monitor a
predicted load or a
measured load of at least one of the first set axle and second sheave set
axle; calculate an
incoming rope tension and an outgoing rope tension; calculate a frictional
characteristic for a
bearing based upon the incoming and outgoing tension; compare the frictional
characteristic to
an acceptable range stored within the non-transitory computer-readable memory;
and perform at
least one of: display a maintenance message on the at least one display,
update the maintenance
log, dispense lubrication, limit an operation of the hoisting machine, and
lower the load; and/or
limit the operation of the hoisting machine to maintain a preset maximum
threshold of a bearing
pressure-velocity or a load-rpm.
[0011] According to another aspect, the non-transitory computer-readable
memory may further
comprise one or more instructions to configure the processing structure to:
maintain a constant
hook height regardless of a boom movement.
[0012] According to another aspect, the non-transitory computer-readable
memory may further
comprise one or more instructions to configure the processing structure to:
calculate a prediction
of a remaining life of the at least one component.
[0013] According to another aspect, the non-transitory computer-readable
memory may further
comprise one or more instructions to configure the processing structure to:
monitor the rotation
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rate of the sheave rotation sensors and perform at least one of: comparing the
rotation
measurement to a predicted sheave rotation rate to detect rope slip or break,
adjusting a rope
wear log, and comparing the hoist machine data to at least one preset
threshold and outputs
warnings or override command inputs to remain within the preset thresholds.
100141 In yet another aspects, the system may further comprise a cable
measurement sensor
measuring a cable distance of a hoist cable being retracted or extended from a
lift winch. The
non-transitory computer-readable memory may further comprise one or more
instructions to
configure the processing structure to: determine the wear of the at least one
component based on
the cable distance measurements; and/or determine at least one of: a sheave
rotation distance, a
sheave rotation rate, a sheave bearing wear rate, and a sheave bearing
remaining life.
10015] According to another aspect, there is provided a lift monitoring system
comprising: a
processor; a transceiver in electrical communication with the processor; a
display receiving
display data from the processor; a human-machine interface transmitting user
control signals to
the processor; the processor executes instructions from a tangible computer-
readable medium to:
receive, by the transceiver, stability data, loading data, positional data,
and velocity data
associated with at least one hoist lifting system for lifting a load;
calculate at least one
adjustment required to increase or decrease a loading moment or a tipping
moment of the at least
one hoist lifting system; detennine at least one suggested command
corresponding to the at least
one adjustment for the at least one hoist lifting system; transmit, by the
transceiver, the at least
one suggested command to the at least one hoist lifting system. The processor
may execute
instructions to receive a margin of safety from the human-machine interface;
retrieve
environmental data from at least one survey database; and/or plan a multi-
machine lifting
operation to account for the environmental data. The environmental data may
comprise at least
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one trench distance, at least one ground slope in lateral and longitudinal
directions, at least one
ground condition, a number of hoist lifting systems, and a type of each hoist
lifting system.. The
margin of safety may account for: an imperfect spacing between the plurality
of hoist lifting
systems, the at least one ground slope, and/or the at least one ground
condition. The at least one
suggested command may be selected from: boom lift, boom lower, load hook lift,
load hook
lower, vehicle forward position adjustment, vehicle back position adjustment,
velocity increase,
and velocity decrease. =
[0016] According to another aspect, the processor may override control of the
at least one hoist
lifting system. The override control may comprise: instructing the at least
one hoist lifting
system to synchronously lift or lower the load to a desired position;
instructing the at least one
hoist lifting system to hold the load stationary; reducing a distance between
the plurality of hoist
lifting systems; lifting or lowering the at least one hoist lifting system in
order to transfer the
load; and/or booming in or out to reduce the loading moment.
[0017] According to yet another aspect, The processor may continuously receive
the stability
data, the loading data, the positional data, and the velocity data; and
calculate a relative stability,
a relative position, and a relative speed of the at least one hoist lifting
system. The processor
may execute instructions to continuously display to the display of the human
machine interface
at least one of: the stability data, the loading data, the positional data,
the velocity data, the
relative stability, the relative position, and the relative speed of the at
least one hoist lifting
system.
=
[0018] According to another aspect, there is provided a hoist lifting system
comprising: at least
one boom coupled by a pivot to a platform, the at least one boom having a
pivot end and a lift
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end; a boom winch located proximate to the platform; a boom cable wound to the
boom winch
and configured to lift the at least one boom; a first block coupled to the
lift end of the at least one
boom, the first block having a first set of sheaves; a lift winch located
proximate to the platform;
a hoist cable wound to the lift winch and passing through the first set of
sheaves within the first
.. block and supported by a first axle; a second block having a second set of
sheaves receiving the
hoist cable from the first block and supported by a second axle; the first set
of sheaves and the
second set of sheaves forming the hoist cable into a plurality of lift ropes;
and a processing
structure determining a wear of at least one component. The wear may be
selected from a
bearing wear, a rope wear, and both the bearing wear and the rope wear. The
processing
.. structure may calculates a prediction of a remaining life of the at least
one component.
[0019] The hoist lifting system may further comprise a rotation sensor
transmitting a rotation
measurement to the processing structure. The hoist lifting system may further
comprise at least
one sensor measuring a hoisting load carried by the first set of sheaves, the
second set of
sheaves, or at least one sheave from the first set of sheaves and the second
set of sheaves.
.. [0020] According to another aspect, there is provided a monitoring device
comprising: a
communication system receiving communications from at least one load moment
indicator
associated with at least one hoist lift system and transmitting communications
to the at least one
load moment indicator; a processing structure operatively coupled to the
communication system;
a display operatively coupled to the processing structure; a human-machine
interface operatively
coupled to the processing structure; a non-transitory computer-readable memory
storing
instructions to configure the processing structure to: receive hoist machine
data from the at least
one load moment indicator; display on the display at least a portion of the
hoist machine data
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from the at least one load moment indicator; and/or determine a stability and
a loading of each of
the at least one hoist lift systems based on the at least one load moment
indicators.
[0021] The non-transitory computer-readable memory may further comprise
instructions to
configure the processing structure to: determine and suggest corrective
actions on the display;
receive human input via the human-machine interface to provide an override
command to one or
more of the at least one hoist lift systems via the communication system;
select an automatic
override and provide the automatic override command to one or more of the at
least one hoist lift
systems via the communication system; and/or coordinate motion of one or more
of the at least
one hoist lift systems. A use of the monitoring device may be used as a lift
planning tool.
[0022] According to yet another aspect, there is provided a method of
monitoring an operational
life of at least one component in a hoist lifting system comprises: winding or
unwinding a hoist
cable, the hoist cable passing through a first set of sheaves within a first
block and supported by
a first sheave set axle; lifting or lowering a second block by winding or
unwinding the hoist
cable, the hoist cable formed into a plurality of lift ropes between the first
set of sheaves and a
second set of sheaves, the second set of sheaves supported by a second sheave
set axle; and
determining, by a processing structure, a wear of the at least one component.
The wear may be
selected from a bearing wear, a rope wear, and both the bearing wear and/or
the rope wear.
[0023] The method may further comprise calculating a prediction of a remaining
life of the at
least one component; receiving, by the processing structure, at least one
sheave rotation
measurement; and/or determining, by the processing structure, the wear based
on the at least one
sheave rotation measurement: The at least one sheave rotation measurement may
be selected
from a sheave rotation distance, a sheave rotation rate, and a combination of
the sheave rotation
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distance and the sheave rotation rate. The method may further comprise
measuring a first load
force on the first sheave set axle; determining, by the processing structure,
a first incoming
tension and a first outgoing tension for at least one sheave within the first
set of sheaves based on
the first load force and the at least one rotation measurement for the at
least one sheave within
the first set of sheaves; determining, by the processing structure, a first
frictional characteristic
for a bearing associated with the first incoming tension and the first
outgoing tension;
comparing, by the processing structure, the first frictional characteristic to
an acceptable range;
recording, by the processing structure to a tangible computer-readable medium,
the first
frictional characteristic into a maintenance database when the frictional
characteristic lies outside
of the acceptable range; displaying, on an operator display, a maintenance
message when the first
frictional characteristic lies outside of the acceptable range; and/or
limiting, by the processing
structure, an operation of a lift winch when the first frictional
characteristic lies outside of the
= acceptable range.
=
100241 The operation may comprise one or more of: limiting the first
frictional characteristic to
the acceptable range by reducing speed of the lift winch; holding the hoist
cable at a fixed length
using the lift winch; dispensing lubrication to the bearing; and/or extending
the hoist cable using
the lift winch in order to safely lower a load.
10025] The method may further comprise measuring a second load force on the
second sheave
set axle; determining, by the processing structure, a second incoming tension
and a second
outgoing tension for at least one sheave within the second set of sheaves
based on the second
load force and the at least one rotation measurement for the at least one
sheave within the second
set of sheaves; determining, by the processing structure, a second frictional
characteristic for the
bearing associated with the second incoming tension and the second outgoing
tension;
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comparing, by the processing structure, the second frictional characteristic
to the acceptable
range; recording, by the processing structure to the tangible computer-
readable medium, the
second frictional characteristic into a maintenance database when the second
frictional
characteristic lies outside of the acceptable range; displaying a second
maintenance message on
the operator display when the second frictional characteristic lies outside of
the acceptable range;
and/or limiting, by the processing structure, the operation of the lift winch
when the second
frictional characteristic lies outside of the acceptable range.
[0026] The operation may comprise one or more of: limiting the second
frictional characteristic
to the acceptable range by reducing speed of the lift winch; holding the hoist
cable at a fixed
length using the lift winch; dispensing lubrication to the at least one
component if the at least one
component is the bearing; extending the hoist cable using the lift winch in
order to safely lower a
load.
[0027] The method may further comprise calculating, by the processing
structure, a first flow
force on the first sheave set axle based on the rotation measurement and a
force measurement
from the load; calculating, by the processing structure, a second load force
estimate on the
second sheave set axle based on the at least one sheave rotation measurement
and a force
measurement from the load; determining, by the processing structure, a second
incoming tension
and a second outgoing tension for the at least one sheave within the second
set of sheaves based
on the second load force estimate and the sheave rotation for the at least one
sheave within the
second set of sheaves; determining, by the processing structure, a second
frictional characteristic
for a bearing associated with the second incoming tension and the second
outgoing tension;
comparing, by the processing structure, the second frictional characteristic
to the acceptable
range; recording, by the processing structure to the tangible computer-
readable medium, the
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second frictional characteristic into the maintenance database when the second
frictional
characteristic lies outside of the acceptable range; displaying, on an
operator display, the
maintenance message when the second frictional characteristic lies outside of
the acceptable
range; and/or limiting, by the processing structure, the operation of the lift
winch when the
second frictional characteristic lies outside of the acceptable range.
[0028] The operation may comprise one or more of: limiting the second
frictional characteristic
to the acceptable range by reducing speed of the lift winch; holding the hoist
cable at a fixed
length using the lift winch; dispensing lubrication to the at least one
component if the at least one
component is the bearing; extending the hoist cable using the lift winch in
order to safely lower a
load.
[0029] According to another Aspects, the method may further comprise
measuring, by a cable
measurement sensor, a cable distance of the hoist cable being retracted or
extended from the lift
winch; determining, by the processing structure, the at least one component
wear based on the
cable distance measurements; determining, by the processing structure, at
least one sheave
rotation distance, at least one sheave rotation rate, or a combination of the
at least one sheave
rotation distance and the at least one sheave rotation rate based on the cable
distance
measurements; and/or accounting, by the processing structure, for changes in
the at least one
component during operation of the hoist lifting system.
DESCRIPTION OF THE DRAWINGS
[0030] While the invention is claimed in the concluding portions hereof,
exemplar aspects are
provided in the accompanying detailed description which may be best understood
in conjunction
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with the accompanying diagrams where like parts in each of the several
diagrams are labeled
with like numbers, and where:
[0031] Figure 1 is a perspective view of a hoist lifting system;
[0032] Figure 2 is a side view of the hoist lifting system in two arm
positions while maintaining
a constant hook height; and
[0033] Figure 3 is close-up perspective view of the blocks of FIGS. 1 and 2;
[0034] Figure 4A is a left side cross-sectional view of the blocks;
[0035] Figure 4B is a left perspective view of the blocks demonstrating a
retraction of the hook;
[0036] Figure 4C is a right perspective view of the blocks demonstrating an
extension of the
hook;
[0037] Figure 5 is a perspective explosion view of a sheave set;
[0038] Figure 6 is a flowchart of a bearing life assessment;
[0039] Figure 7 is a flowchart for maintaining a constant hook height;
[0040] Figure 8 is a flowchart for determining component loading;
[0041] Figure 9 is a flowchart for determining bearing wear/pileup and bird
caging;
[0042] Figure 10 is a perspective view of pipe layer machine comprising a
hoist lifting system
mounted on a mobile platform;
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[0043] Figure 11 is a perspective view of a plurality of hoist lifting systems
and a block diagram
of the hoist lifting systems in communication;
[0044] Figure 12 is a perspective view of the plurality of hoist lifting
systems in communication
with a lift monitoring system;
.. [0045] Figure 13 is a flowchart for lift planning of the plurality of hoist
lifting systems;
[0046] Figure 14 is a flowchart for lift monitoring of the plurality of hoist
lifting systems; and
[0047] Figure 15 is a flowchart of a rope life assessment.
DETAILED DESCRIPTION
[0048] Many load-lifting devices are subject to compliance with strict
standards that are intended
to ensure component reliability and safety for the workers and public. In the
absence of detailed
measurements about equipment conditions between maintenance intervals,
operators and
maintenance planners make assumptions when deciding on maintenance and
inspection
activities. Frequently, these activities are run on a set time schedule, such
as replacing
components after a certain number of hours of service and performing
inspections after a certain
number of months. These simple schedules often cannot account for the degree
of service to
which the equipment was subjected and therefore can lead to over-maintenance
of lightly used
equipment or under-maintenance of heavily used equipment. Furthermore, simple
schedules
permit equipment to remain in service despite having been subjected to an
undetected
overload(s) that would require re-inspection. A lack of reliable information
also makes
continuous improvement of maintenance practices difficult. The aspects
described herein relate
to systems and processes for monitoring and/or predicting the state of various
components and
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aspects of a load lifting system in order to generate accurate information to
perform informed
maintenance and inspections.
100491 As presented in FIGS. 1 to 3, there is provided a hoist lifting system
100 for lifting pipes
or other heavy loads. The hoist lifting system 100 comprises at least one boom
108 that may be
coupled, using a pivot 240, to a platform 1102 (as seen in FIG. 10). The one
or more boom(s)
108 may be raised or lowered using a boom winch 1112 through rotation of the
pivot 240. The
boom winch 1112 may be located proximate the platform 1102. In an aspect, the
pivot 240 may
be rotated by a boom cable (not shown) that winds and unwinds from the boom
winch 1112. A
boom encoder (not shown) may measure a rotation angle of the boom 108 about
the pivot 240.
In this aspect, the boom 108 comprises a pair of parallel arms having a
proximal end 1118 (e.g.
pivot end) and a distal end 1120 (e.g. lift end), where the pivot 240 may be
located near or at the
proximal end 1118. Other aspects may have a single arm or more than two arms.
At or near an
end of the boom 108 opposite the pivot 240 may be a first block mount 102
where a first block
114 may be hung using a becket 202. A second block 112 may be hung from the
first block 114
using a plurality of lift ropes 116. The plurality of lift ropes 116 may be
formed by passing a
hoist rope 120 through at least two sets of sheaves 602. The second block 112
may comprise a
hook 122 or other type of attachment for fastening to loads. The first block
114 and the second
block 112 may comprise one or more pin(s) 110 that may support the set of
sheaves 602, shown
more clearly in FIG. 5 and described in further detail below.
[0050] In this aspect, a winch or winding drum 104 (e.g. a lift winch) may be
located on a
slewing platform (not shown) and/or mounted on a mobile platform 1102. In
other aspects, the
winch drum 104 may be located on a fixed platform (not shown). The winch drum
104 may be
rotated using a motor (not shown) in order to retract or extend a hoist rope
(or cable) 120 that
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may pass through the first block 114. The retraction or extension of the hoist
rope 120 through
the first block 114 may cause the second block 112 (e.g. the hook block) to be
raised or lowered
using the plurality of lift ropes 116.
[0051] In this aspect, the winch drum 104 may also comprise a lift winch
sensor 106 (e.g. a lift
winch encoder) that may measure a number of rotations of the winch drum 104 or
motor. In
some aspects, the lift winch sensor 106 may measure the number of rotations of
a gear (not
shown) between the winch drum 104 and the motor. The number of rotations may
generally
correspond to a length of hoist rope 120 retracted or extended and/or provide
measurements of
the hoist rope 120 line speed and thus relative displacement of the second
block 112. In another
aspect, a linear encoder may be used to measure the length of hoist rope 120
retracted or
extended. When used in combination with a position sensing system 1302, as
described in
further detail with reference to FIGS. 10 to 11 below, an operator may choose
a hook height 214
(e.g. lift height) to be maintained despite movement in a position of the boom
108 or travel of the
platform 1102. A baseline position may be set by the operator and saved into a
tangible
.. computer-readable medium (e.g. a memory) by a processing structure, such as
a controller 1206.
From the baseline position, a relative displacement may be determined from
raising or lowering
of the boom 108 or changes in a ground angle as describe in further detail
below and in CA
2,974,819 filed on July 28, 2017 and U.S. Prov. App. No. 62/538,966 filed on
July 31, 2017,
both of which are herein explicitly incorporated by reference in their
entirety. A change in the
relative displacement may be compensated for by spooling in or out the winch
cable 120, within
a range of motion possible without causing the first block 114 and second
block 112 to come into
contact.
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[0052] As presented in FIG. 2, the boom 108 may rotate about the pivot 240
from a first angle
220 to a second angle 222 or vice versa. In order to maintain a generally
constant height 214 of
the hook 122, a length 216, 218 of the lift ropes 116 may be shortened or
lengthened using the
hoist rope 120 depending on the rotation of the pivot 240. For example, with
reference to FIG. 7,
a desired hook height 214 may be set by the operator or the lift supervisor
(step 802). A change
in the position of the boom 108 position may then be measured using a boom
encoder
operatively coupled to the boom winch 1112 at step 804. An adjustment of the
hook height 214
may be calculated at step 806. A pay-in or pay-out may then be determined for
the lift ropes 116
at step 808. For example, if the pivot 240 is rotating the boom 108 from the
first angle 220 to the
second angle 222, then the length of the lift ropes 116 may be extended. In
another example, if
the pivot 240 is rotating the boom 108 from the second angle 222 to the first
angle 220, then the
length of the lift ropes 116 may be retracted.
100531 For step 806, the adjustment of the hook height 214 may involve the
following. When
the boom 108 is moved from one lift position (xi, yi) to a second lift
position (x2, y2) with
respect to the location of the load-lifting winch drum 1112 (x3,y3), a
distance between the load-
lifting winch drum 1112 to the first block 114 changes. If the load lifting
winch 104 is not
wound in or out accordingly, the hook 122 is raised or lowered accordingly,
which may increase
or decrease the amount of load being supported by the load lifting system 100.
This unexpected
load change may cause instability of the load lifting system 100, premature
wear, and/or
overload of components, and other problems. By predicting this height change
and
automatically adjusting the load lifting winch 104 accordingly, these problems
may be avoided
or reduced.
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[0054] A change in the distance between the first block 114 and the load
lifting winch 104 may
be determined by the movement of the first block 114 using an x-y coordinate
system as labelled
above.
With N equal to the number of line parts between the first block 114 and the
second block 112, if
the second block 112 stays in the same location in the y-direction (e.g.
desired condition), for a
boom of length, d, and angle, 0, a winch rotation angle, y, and drum
instantaneous radius, rw,
and the total amount of rope 120 that may be winched in or out is:
6Lwinch, = Mboom + Mblock
= (II (X1 ¨ x3)2 + (y1 ¨ y3)2 ¨ V(x2 ¨ x3)2 + (y2 ¨ y3)2) + N(y2 ¨ yl) '
And the required lift winch adjustment angle is:
180 2 2.
,
Ay = ¨ [NIV/fli cos 01 ¨ x3) + (4,1 sin 01 ¨ )13)
n-rw
¨ cos 02 ¨ x3)2 + (c//32 sin 02 ¨ y3)2 + N(d/32 sin 02 ¨
dfli sin 001
[0055] The lift winch encoder 106 may be used to determine the extension or
retraction length
and/or may be used to determine the extension or retraction velocity (e.g.
line speed). In other
aspects, one or more motor parameters may be used to further calculate the
extension and/or
retraction velocity.
[0056] The location of the boom 108 may be measured and the rotation of the
lift winch 104
tracked in order to allow an operator to set a desired height 214 of the
second load block 112 and
may have the desired height 214 maintained consistently regardless of how the
boom 108 may be
CA 3012498 2018-07-27
18
moved. Changes in the hook height 214 due to motion of the boom 108 or the
platform 1102
(e.g. vehicle motion) may be calculated and the lift winch 104 wound or
unwound to maintain a
constant hook height 214. In a multi-machine lift environment, such as shown
in FIGS. 10 and
11, the relative height of each load lifting point may correspond to the
amount of load being
.. lifted by each hoist lifting system 100. Thus, maintaining a constant hook
height 214 may ensure
a consistent hoisted load for each machine 1104 and may prevent overloads,
premature
component wear, and/or instability.
10057] Turning now to FIGS. 4A to 4C, there is provided a close up view of the
first block 114,
second block 112, and the lift ropes 116. The first block 114 may comprise a
shell 402 coupled
to the becket 202. Within the shell 402 may be the set of sheaves 602
rotatably coupled to the
pin 110 so that the set of sheaves 602 may freely rotate. Each sheave 602 may
have a sheave-
rotation monitoring sensor 604, such as an encoder, pulse-pickup sensor, or
other similar sensor,
which may provide a direct measurement of the rate and/or distance at which
each sheave is
rotating. In some aspects, only the sheave 602 that may experience the highest
bearing wear may
be monitored with the sheave-rotation monitoring sensor 604. The lift rope 116
may pass
through each sheave 602 within the first block 114 and the second block 112.
When the hoist
rope 120 is retracted with a tension Ti and velocity Vi, as is shown in FIG.
4B, the lift ropes 116
experience tensions T3, T5, T7, and T9. The lift ropes 116 also retract at
velocities V2, V3, V4,
and V5. Similarly, with reference to FIG. 4C, when the hoist rope 120 is
extended at velocity V1
and tension T1, then the lift ropes 116 extend at velocities VI, V2, V3, and
V4 with tensions Tz,
T4, T6, and Ts respectively. The tensions, T, and velocities, lin, may be
determined using the
method as set forth below.
CA 3012498 2018-07-27
19
[0058] The ratio of the speed of a first part of winch rope 120 to the speed
of the second block
112 is:
Vwinch = N = Vblock
where N is the number of pulleys. N is also equal to the number of lift rope
116 lengths running
between the first block 114 and the second block 112 (e.g. line parts). The
speed of each part of
line 116 and thus the rotational speed of each sheave 602 may be different and
depends on the
sheave's position in the second block 112. With the first sheave 602 numbered
1, the second
sheave 602 numbered 2, and the nth sheave 602 numbered, n, and N being the
total number of
sheaves 602, and Vbiock being the speed of the second block 112, the rope line
speed, Vn, at each
sheave 602 is given by:
N+ 1 ¨ n)
Võ = _____________________________________ x VW inch
[0059] The tension in each line part 116 may be different due to friction in
the bearing(s) and/or
the lift ropes 116. The sheave friction and rope tension may be calculated by
the force, Fp on the
pin 110 as measured by a force sensor (on one or more of the load pins), which
comprises an
incoming tension, T, and an outgoing tension, T,. The outgoing tension, T,,
may comprise the
difference of the incoming tension, Ti, and a friction torque, Tf. The change
in tension from
friction may be determined by:
=
Tf ¨ ¨ Ff
Ts
CA 3012498 2018-07-27
20
where is the ratio of a radius, rp, of the pin 110 to a radius, rs, of
the sheave 602, and the
rs
friction force Ff is given by:
Ff = Fpitf
where p.f. is the coefficient of friction between the sliding surface of the
bearing and the pin
and/or the coefficient of rolling resistance of the bearing balls/rollers and
the bearing races, or
other factor corresponding to the mechanical efficiency of the rotation. This
friction coefficient
may comprise tabulated, simplified values such as for sliding friction between
two materials and
their lubricity and/or generic bearing friction values, or more explicit
methodologies accounting
for tribological factors and/or specific bearing parameters such as race,
cage, rolling-element
geometries, etc.. The pin force Fp may be determined by:
2Ti
F __ +
kUf
and the outgoing tension, T,, then becomes:
¨ f
To = __ rp
1 + f
where
2Ti ¨ Fp
= __________________________________________
F
P rs
CA 3012498 2018-07-27
21
100601 Therefore, when going from one sheave 602 to the next, one sheave's
outgoing tension,
T,, is equal to the next sheave's incoming tension, Ti. The sheave pin 110 and
the rope tension
equations for any sheave number, n, may be:
F
= p(n) ( rp (n)
T (n) __ 1 4- f (n) = T0(_1)
2 rs(n)
where
2Ti(n) 2T0(_ l)
F ¨ _______
P (n) rp(n) rpoi)
1 + [1 f(n) --,.. 1 4- f (n)
s(n) soi)
therefore
(1 ¨ yfin) rP(n) 1 Pf(n) rii(n)
r s(n) rsoo
To(n) = Ti(n) = Too_1) i
rpo.,) rp(n)
f (7,) r _____________________________ s (n) 1 + f (n) __
r s(n)
and
2Ti(n) ¨ Fp(n) 27'0(71_1) ¨ Fp(õ)
(n) = rp(n)
rP(n) Fp(n) r5(fl) F P(.1) rs(n)
The frictional characteristic of each sheave from 1 to n, with the winch
tension denoted as TN,
then the frictional characteristic equation for sheave bearing, n, is
rp(n)
Fp(p) 1 ¨ Pf(n)
Sf(n) = r rp(n)
rp(n-1) _L
s(n)
CA 3012498 2018-07-27
22
And the solution of sheave bearing, n, load is:
71-1
F(n) = Tw psf(i.,)+H S f (,)1
allowing solving for the friction based on the measured pin force when they
cannot be directly
measured.
F fro r
Where ___ P" = F.,.(p) and P (n) = 7-7.(2) resulting in:
Fp(n-i) rs(n)
1 P (n)
= ¨ Fr(.") F(_1)
r(n)(Fr(n) -1- 1) r p (n) )
r s (n) F(_1)
may allow for simultaneous measurement of the load induced in each of multiple
loading faces.
[0061] Without feedback regarding the load and/or friction of each sheave, and
as long as the
sheaves and bearings are nominally the same, the following assumptions may be
made:
I1f= Pm) = Itf(2) =
rp = rpm = 1p(2) = ===
rs = rs(i) = r5(2) =
Resulting in
F(n) = Tw[Sf n-1 + S
Therefore,
CA 3012498 2018-07-27
23 =
V = h
Pf(n) = f1fTw[Sfn-1 Sfnj _________________ winc N (N + 1 ¨ n) ¨
rs
[0062] Comparisons between the measured loads, along with formulas derived
from the
fundamental mechanics of sheaves 602, may allow for a computing structure 1302
to calculate
frictional losses in each bearing. These friction coefficients may be compared
with baseline
values. In this aspect, the comparison determines whether the friction
coefficients are within an
acceptable range. In other aspects, the friction components may be compared to
a threshold or a
preset tolerance. These calculations may then allow monitoring of an
operational life of the
sheaves 602. The comparison may be used to determine that the bearings have
worn, suffered a
catastrophic failure such as seizing or spalling, and/or detect if the hook
122 is unable to lower
under its own weight. If the hook 122 does not move despite rope 120 being
paid out by the
winch 104, a loss of tension in the rope 120 between the winch 104 and blocks
114, 112 may
occur leading to improper winch reeving and, if left unchecked, bird-caging of
the winch drum
104 and potential rope 120 kinking and/or seizure.
[0063] Through the measurement of the load weight and the line speed, a
theoretical load and
bearing surface velocity may be determined for each of the individual bearings
(e.g. plain and/or
rolling contact) of the sheaves 602. The line speed measurements may also be
used to adjust a
theoretical friction factor to account for bearing surface speeds. The
combination of the line
speed measured by the winch encoder 106 and the measured bearing loads may
allow for
increased data on a state of the sheaves 602. Individual pressure-velocities
may be calculated for
each plain bearing, and load-rotations calculated for rolling-contact
bearings. Rotational speed
and friction-factors may be calculated from the sensed loads to yield the
frictional power losses
= in each bearing, and thus the heat being generated.
CA 3012498 2018-07-27
24
[0064] With the use of an individual sheave load monitoring device, a current
state of the
components, such as the bearings and rope, may be monitored in order to detect
and/or predict
failure states by additionally measuring individual bearing frictions and
loads. If the friction,
of the bearing or entire block as calculated from the measurements of the
individual load
monitoring device deviates from the allowable ranges as stored in the
computing structure 1302
(as described in further detail below), then the computing structure 1302 may
display an
indication that the bearing element may have worn excessively, failed
catastrophically, needs
additional lubrication, suffers from environmental contamination, and/or other
types of failure or
pre-failure. The computing structure 1302 may operate an automatic lubrication
system, output a
warning, reduce the load or speed of the components, call for an inspection,
and/or other forms
of remedial action.
[0065] In addition to detecting and predicting failures in the components,
additional failure
modes may be detected, such as a broken rope 120 or bird-caging/rat-nesting
hoist drum 104. If
the winch 104 is paying out and the measured load in the furthest sheaves 602
increases
substantially while the load in the closest sheaves 602 decreases to zero or
near zero, this may
indicate that the tension is not being normalized between the cable lays
within the expected
range as detailed by theoretical friction factors and thus the rope 120, 116
may be bird-caging
(e.g. paying out cable 120, 116 without a corresponding lowering of the hook
block 112). A
sudden reduction in bearing loading may indicate that the rope 120, 116 may
have broken and
the hook block 112 may be free-falling.
[0066] In other aspects, one or more critical operational parameters of each
element, such as the
load, pressure, velocity, and friction of rolling or sliding elements inside
the rigging blocks 112,
114 may be determined and/or tracked over time to build an accurate record of
each rolling
CA 3012498 2018-07-27
25
element bearing, plain bearing, or rope operational history. For example,
service information
may be used to monitor the force applied to a bearing or rope 120, 116, a
number of rotations of
the bearing and/or a number of bending cycles of the rope 120, 116 and/or
detecting and warning
of overload conditions, component fatigue, etc. Measurements of the ground
slope may be, used
to account for out-of-plane loads and additional twisting or bending induced
in structural
members (such as the boom 108). The conditions may be compared to thresholds
set by
pertinent operational standards to ensure compliance and/or warn of
violations.
10067] For example, with reference to a bearing life process 700 presented in
FIG. 6, an estimate
of a bearing life may be determined. The process 700 starts by initializing a
bearing life counter
(step 702). A load may then be measured and/or calculated using the processing
structure 1302
at step 704. The winch speed may be measured using the winch encoder 106 as
previously
described (at step 706). From the measured load and the winch speed, the line
speed may be
calculated at the sheaves 602 and/or the bearing surface sliding speed
(distance per unit time)
and/or rotations-per-minute (RPM) (step 708). To further improve accuracy, it
may be measured
at each or some sheaves by a sheave encoder or pulse-pickup sensor or other
similar sensor 604.
A discrepancy between the sheave rotation rate calculated from the measurement
of the winch
encoder 106 and the position of the sheave within the hoisting system may
indicate the rope is
sliding along the surface of the sheave 602 rather than the sheave 602
rotating on the pin 110.
The increment to the bearing life counter and rope life counter may be made
accordingly, as this
condition is substantially different than the normal operating condition. To
further improve
accuracy, environmental information may be determined at step 710. The bearing
life counter
may be updated at step 712. If the bearing life counter exceeds a bearing life
threshold (step
714), a message may be output on a display and/or sent to a mobile phone or
other device (not
CA 3012498 2018-07-27
26
shown) via a SMS message and/or other type of notification at step 716.
Corrective action may
be taken at step 718, such as inspecting and/or changing the bearing. In other
aspects, the winch
motor may be deactivated until the bearing life counter is reinitialized at
702. If the bearing life
threshold is not exceeded, then the process 700 returns to step 704. In other
aspects, this process
700 may be peiformed without obtaining measurements directly for each bearing
element, but
rather calculating an estimated load in each bearing by applying estimated
friction factors and
using the known load calculated from the lift monitoring system as disclosed
by CA 2,974,819
and U.S. Prov. App. No. 62/538,966, and the winch speed from the winch encoder
106 and/or
sheave rotation speed information from sensors 604.
[0068] Similarly, with reference to FIG. 15, a rope 120, 116 life process 1600
may determine an
estimate of a rope life. The process 1600 begins by initializing a rope
element life counter (step
1602). A load may be measured and/or calculated using the processing structure
1302 at step
1604. The rope element position may also be measured and/or calculated at step
1606. The
winch speed may be measured using the winch encoder 106 as previously
described (at step
1608) and the individual sheave rotation speeds from the sensor 604 as
previously described.
From the measured load and the winch speed, the line speed, flex state, and/or
load of the rope
element may be calculated (step 1610). To further improve accuracy,
environmental information
may be determined at step 1612. The rope life counter may be updated at step
1614. If the rope
life counter exceeds a rope life threshold (step 1616), a message may be
output on a display or
sent to a mobile phone (not shown) via a SMS message or other type of
notification at step 1618.
At step 1620, corrective action may be taken, such as inspecting and/or
changing the rope
element. In other aspects, the winch motor may be deactivated until the rope
life counter is
CA 3012498 2018-07-27
27
reinitialized at 1602, such as after an inspection of the rope. If the rope
life threshold is not
exceeded (step 1616), then the process 1600 returns to step 1604.
[0069] Returning to another example demonstrated in FIG. 8, a component load
determination
process 900 is presented. The process 900 begins by calculating or measuring
component
positions at step 902. A ground slope may be measured at step 904 using
accelerometers, tip
switches, or the like, as disclosed by CA 2,974,819 and U.S. Prov. App. No.
62/538,966. Using
the component positions and the ground slope, a set of external loads and/or
vectors may be
determined for the hoist lifting system 100 at step 906. A set of internal
loads 908 may be
calculated using the processing structure 1302 at step 908 and described in
further detail below.
The internal loads may then be compared with a set of thresholds at step 910.
If one or more of
the thresholds has been exceeded, the processing structure 1302 may execute
one or more of the
following: outputting a warning, logging an incident, limiting motion of the
hoist lifting system
100, storing the incident in a data log file, and/or performing corrective
action (immediate or
otherwise) at step 912 and described in further detail with reference to FIG.
14 below. In some
aspects, the warning may be transmitted to a lift monitoring system 1312.
[0070] Calculating external loads may be complicated when there is no ability
to mount a load-
measuring sensor directly at the load application point and the processing
structure 1302 may
have to imply the external load based on the measurements from other
locations/components.
This may require the processing structure 1302 to account for the weights and
positions of the
hoisting machine in order to determine an estimate of the external loading.
This may be further
complicated when aspects of the hoisting machine 1100 may not necessarily be
constant
throughout the lifting process. The lengths of cable may be spooled on winch
drums and may be
paid out to lower the load or adjust the position of a lifting support
structure 100 such as a boom.
CA 3012498 2018-07-27
28
In such cases, the weight of cable and its associated center of gravity may be
shifted in position
and accordingly have an effect on the righting moment and/or tipping moment of
the hoisting
machine 1100.
[0071] With N equal to the number of line parts between the first block 114
and the second block
112, if the second block 112 stays in the same location in the y-direction
(e.g. desired condition),
for a boom of length, d, and angle, 0, a winch rotation angle, y, drum
instantaneous radius, ri, a
distance between the first load block and second load block dffioth, and rope
weight per unit
length Wr, and the external load effective weight change from paying the rope
120 in or out is:
6.Wrope = Wr X dBlocks X N
Th-r,
Wrope = Wr x Ay x -180
For a system where the boom has moved from an angle Olt 02 while maintaining
a constant
hook height above the ground surface:
,z
A Wrope = Wr X . j(digi COS 91¨ X3) + (C1/31 sin ei ¨ y3)2
¨ \I(42 cos 02)2 + (42 sin 02 ¨ Y3)2 + N(42 sin 02 ¨ dm) . I
where the weight of the rope is moved from the winch drum location to the
location of the
external load application point.
[0072] In a similar fashion, variations in the distance between the first set
of sheaves and second
set of sheaves has an effect on the load carried by each sheave and bearing as
the upper sheaves
carry the weight of the rope suspended beneath them. This situation affects
frictional
CA 3012498 2018-07-27
29
characteristic of each upper sheave bearing as the additional rope weight
causes an increased
friction force. As informed by the weight transfer formulas above, the
corresponding sheave
bearing loads may be adjusted to account for the weight of the suspended ropes
by applying
offset values to the sheave load and friction formulas described above.
[0073] In yet another example shown in FIG. 9, bearing wear/pileup and/or bird
caging detection
process 1000 is presented. In step 1002, one or more external loads may be
obtained as
disclosed by CA 2,974,819 and U.S. Prov. App. No. 62/538,966. One or more
measurements
may be used to measure the individual loads on each of the sheaves 602. The
winch direction,
line speed, and/or individual sheave speed may be measured at step 1006.
Through these
measurements, one or more friction coefficients may be calculated by the
processing structure
1302 for each sheave 602 at step 1008. These one or more friction coefficients
may further be
modified at step 1010 using one or more measured environmental conditions. A
comparison of
the loads and friction coefficients to the theoretical values from materials
science normative
references, testing results, and/or data logged from previous operations of
the equipment may
then be peifonned at step 1012. If the friction coefficients and/or the loads
differ significantly
from the comparison values, then an output warning or maintenance trigger may
be set at step
1014. The warning or maintenance trigger may initiate an inspection of the
hoist lift system 100.
In some aspects, the warning or maintenance trigger may be transmitted to the
lift monitoring
system 1312.
[0074] The bearing wear may be estimated using the equations presented in
Machine Elements
in Mechanical Design (4th edition) by Robert L. Mott, herein explicitly
incorporated by reference
in its entirety, or via similar wear-load formulations such as those from the
ASME Wear Control
CA 3012498 2018-07-27
30
Handbook, Peterson and Winer, herein explicitly incorporated by reference in
its entirety. The
material wear factor may be determined by:
k = ¨
FVT
where k is the material wear factor, w is the wear (e.g. loss of weight or
volume), F is the applied
load, V is the surface velocity, and T is the time of operation. The load-life
relationship for a
rolling contact bearing may be expressed as:
D
Lz = k
L 1
L1 P2
where L is the life, P is the load, and k is the bearing factor (e.g. 3 for
ball, 3.33 for roller). From
the Palmgren-Miner rule, the main effective load is:
FM= [Ei(FDPNir
[ N
is the individual load among a series of i loads, Ni is a number of
revolutions at which Fi
operates, N is the total number of revolutions in a complete cycle, and p is
the load-life exponent
(e.g. 3 for ball, 3.33 for roller), and C the basic dynamic load rating for
the bearing. Therefore,
L = (C )P
= CP (Ei(FNOPN i)
Energy is force times distance and thus, the heat generated by friction Q f =
Ffds where ds is the
distance travelled at the sliding surface. The power loss due to friction is:
CA 3012498 2018-07-27
31
rp (n)
Pfn = Ff Vs = pf(n) (n) Ls(n)
rs(n)
where v, is the surface speed, Pfn is the frictional power loss in sheave n,
jifn. is the coefficient of
friction in sheave n, Fpn is the total load carried by sheave n, Lsn is the
rope line speed at sheave
n, rpn is the p in outside diameter at sheave n, and 7-5n is the pitch
diameter of sheave n.
The friction coefficient was previously defined as:
1 Fp(n)
Fp(n_1)
f (n) = ___________________________________ Fp(n)
p(n) (1 + _____________________________________
rs(n) Pp(n-1))
=
and
Vwinch = N x Vb lock
Vn = Ls(n) = (N + 1 n)Vblock
N+ 1 ¨ n
Vn = ____________________________________ x VW inch
Therefore, the frictional power loss in an individual bearing may be expressed
as:
p(n)
_[1 F(1) Fp() vwinchN + 1 ¨ n)
1+ P =
Pf (n) F (n) 71 N
p(n- 1)
[0075] Through monitoring of the individual bearing loads, direct maintenance,
inspection, and
replacement activities may be directed. For example, the monitoring may
initiate control of an
CA 3012498 2018-07-27
32
automatic lubrication system (not shown) that dispenses lubrication based on a
component's
service duration and severity. Following the injection of additional
lubrication, the monitoring
system may further monitor the measured friction coefficient to detect if the
factor has been
reduced that may indicate an environmental issue such as contamination or
dryness has been
addressed. If the factor has not been reduced, this may indicate a bearing
failure.
[0076] Although the aspects herein describe a generally stationary system, the
aspects may
equally be applicable to the components, systems, and operational behavior of
other types of
hoisting equipment, including but not limited to: pipe-laying side-booms,
mobile cranes,
stationary cranes, dragline miners, etc.
[0077] Although the aspects herein demonstrate a pair of parallel arms for the
boom 108, other
aspects may have the arms interconnected to each other between the pivot 240
and the mount
102 at the end of the boom 108. In some aspects, the mount 102 may not be
located at the end of
the boom 108.
[0078] FIG. 10 illustrates a pipe layer machine 1100, in this particular
aspect, the pipe layer
machine 1100 may comprise the hoist lifting system 100 as previously
described. The pipe layer
machine 1100 may place sections of pipe 1202 in a trench. The pipe layer
machine 1100 may
include a main body or platform 1102, an engine 1104, a first side track 1106,
a second side
track 1108, a cab (not shown), a side boom 108, a counterweight assembly 1110,
a boom winch
1112, a lift winch 104, and a hook 122.
[0079] The main body 1102 may have a boom side 1114 and a counterweight side
1116 and hold
the engine 1104 and the pair of tracks 1106, 1108. The cab (not shown) is
provided for an
operator to sit and control the operation of the pipe layer machine 1100.
CA 3012498 2018-07-27
33
[0080] The side boom 108 may be used to support a pipe section 1202 that may
be lifted off of
the ground by the pipe layer machine 1100 and to move the pipe section 1202
laterally 'away
from the pipe layer machine 1100 over top of the trench so that the pipe
section 1202 may be
lowered by the pipe layer machine 1100 into the trench (not shown). The side
boom 108 may be
pivotally connected at a proximal end 1118 of the side boom 108 to a boom side
1114 of the
main body 1102 of the pipe layer machine 1100 so that the side boom 108
extends laterally from
the boom side 1114 of the main body 1102. In one aspect, the proximal end 1118
of the side
boom 40 may be connected inside the boom side track 1106 on the boom side 1114
of the main
body 1102 so that the boom side track 1106 rotates around the proximal end
1118 of the side
boom 108.
[0081] In one aspect, the side boom 108 may have a generally triangular frame
or an A-frame.
[0082] The boom winch 1112 may be used to raise and lower the side boom 108.
The boom
winch 1112 may be operatively attached to a distal end 1120 of the boom 108 by
a boom cable
(not shown). The boom winch 1112 may be attached to the main body 1102 of the
pipe layer
machine 1100 so that the boom cable may pass between the boom winch 1112 and
the distal end
1120 of the side boom 108 in front of the cab (not shown) of the pipe layer
machine 1100.
[0083] The boom winch 1112 may be wound to raise the boom 108 around the
pivots 240
connected proximal end 1118 or unwound to lower the boom 108 around the pivots
240
connected to the proximal end 1118.
=
[0084] The boom cable may be used in conjunction with a block and tackle
assembly (not
shown) to increase the force applied to the boom 108 by the boom winch 1112 to
aid the boom
winch 1112 in raising the boom 108. A luff block (not shown) may be pivotally
attached to the
CA 3012498 2018-07-27
34
main body 1102 of the pipe layer machine 1100, near the boom winch 1112. The
luff block may
pivot up and down at a pivot point where it may be connected to the main body
1102 of the pipe
layer machine 1100. A boom block (not shown) may be provided pivotally
attached to the distal
end 1120 of the boom 108 by a boom block pin (not shown) so that the boom
block may pivot
upwards and downwards around the boom block pin. The boom cable may run back
and forth
between the luff block and the boom block 102 to form a block and tackle
system that may
multiply the force that the boom winch 1112 is applying to the distal end 1120
of the boom 108.
The boom cable may run back and forth between the luff block and the boom
block 102 four (4)
times, but it could be run fewer or more times depending on the number of
pulleys provided in
each of the blocks.
[0085] The lift winch 104 and hook 122 may be used to raise and lower a pipe
section as
previously described for the hoist lifting system 100. The lift winch 104 may
be connected to the
hook 122 with a hook cable 120 and the lift winch 1112 may be wound to raise
the hook 122 and
thereby any pipe section attached to the hook 122 or unwound to lower the hook
122.
[0086] The hoist cable 120 may be used with a block and tackle assembly (e.g.
112, 114, 116,
and 110 in FIG. 1), as previously described, to increase the force the lift
winch 1112 may apply
to the load attached to the hook 122. With the hoist cable 116 connected to a
load block 114
connected to a distal end 1120 of the boom 108 and a hook block 112 that the
hook 122 may be
provided on.
[0087] The counterweight assembly 1110 may be connected to the counterweight
side 1114 of
the main body 1102 on an opposite side of the main body 1102 from the boom
side 1116. The
counterweight assembly 1110 may be used to counterbalance the forces applied
to the pipe layer
CA 3012498 2018-07-27
35
machine 1100 created when the pipe layer machine 1100 lifts a pipe section
1202 off of the
ground and moves it outwards laterally from the pipe layer machine 1100 using
the boom 108 to
position the pipe section 1202 over a trench. The counter weight assembly 1110
may use
counterweights 1122 and may move these counterweights 1122 laterally away from
the
counterweight side 1114 of the main body 1102 of the pipe layer machine 1100
before the pipe
section is picked up and moved laterally away from the boom side 1116 of the
main body 1102
of the pipe layer machine 1100.
[0088] Now with reference to FIGS. 11 to 12, pipe layer machine 1100 with
hoist lifting systems
100 may operate by participating in a team lift of a load 1202 (e.g. pipe)
that exceeds any one
capacity of an individual hoist lifting system 100 and/or pipe layer 1100.
Each individual hoist
lifting system 100 may be lifting a different portion of the load 1202, and
the load force .for a
particular hoist lifting system 100 may vary significantly depending on a
position of the mobile
platform 1102, position of the boom 108, lift winch inputs, the size and
specification of the pipe
layer machine 1100, ground conditions, distance from the trench, etc. Lift
management, such as
planning a number, specification, placement of the pipe layers 1100 may be
determined by one
or more standard lift charts provided by the equipment manufacturer. Standard
lift charts are
typically for level ground and may not account for optional equipment that may
be installed on
the pipe layer 1100 and/or hoist lifting system 100. Moreover, standard lift
charts do not account
for varying ground conditions.
[0089] In practice for prior multi-machine lifts, once a lift is in progress,
a lift supervisor may
communicate with one or more operators to coordinate the lift using handheld
radios. This
practice results in errors through miscommunication and/or cross-talk
resulting in time delays.
The operators may monitor the pipe layer machines 1100 using a load moment
indicator (LMI)
CA 3012498 2018-07-27
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1304 that indicates how close the hoist lifting system 100 may be to tipping
over. In other
aspects, the operator may additionally be provided with how much load 1202
currently being
lifted by the hoist lifting system 100. The lift supervisor does not have
direct access to this lift
data, which limits coordination of the lift and/or does not ensure all
machines are operating
within their tolerances or in an optimal configuration.
[0090] A dynamic tipping moment indicator system 1200 comprising a plurality
of hoist lifting
systems 100 may be mounted on a plurality of mobile platforms 1104. In this
aspect, the hoist
lifting systems 100 may be lifting a load 1202 comprising a pipe (or pipe
section). Each of the
hoist lifting systems 100 may measure or calculate a plurality of boom
coordinates (x1, yj, zi) to
(xn, y, zn). Each hoist lifting system 100 may measure a load force vector F1
to F. A distance
c11 to dn of the pipe layer machine 1100 from the load 1202 and the velocity
vector 171 to Vn of the
pipe layer machine 1100 may also be measured by such methods as GPS modules,
radar, lidar,
ultrasonics, or calculated by such methods as accelerometer dead-reckoning.
Each hoist lifting
system 100 may determine a distance 42, d2,3... dn../,n to the next mobile
platform 1102 by such
methods as GPS modules, radar, lidar, ultrasonics, near-field communication,
or calculated by
such methods as accelerometer dead-reckoning. In the example 1200 presented in
FIG. 11 and
the example 1300 presented in FIG. 12, there are three hoist lifting systems
100, but there may
be more or fewer hoist lifting systems 100. At least a portion of the data
measured and/or
generated by each of the hoist lifting systems 100 may be provided to a lift
planning and
monitoring system 1250 using data communication (e.g. wired or wireless). The
lift planning
and monitoring method and system 1250 may monitor, provide warnings, override
unsafe control
actions, and/or synchronize each of the hoist lifting systems 100 as described
in further detail
below.
CA 3012498 2018-07-27
37
[0091] Each hoist lifting system 100 may comprise a processing structure 1302
having a lift
moment indicator 1304, a controller 1306 (having at least one processor and
computer-readable
memory), a plurality of position and velocity sensors 1308 and a transceiver
1310 to
communicate. Each processing structure 1302 may measure and/or calculate
external loads and
vector projections into a principle plane of the hoist lifting system 100. The
choice of principle
planes may be selected reduce computational complexity depending on the
specific operation
being done by the processing structure 1302. The processing structure 1302 may
use these
measurements from the lift moment indicator 1304 and/or the measurements of
each individual
bearing face to determine a live load induced in structural members, such as
for example the
boom 108, as described above.
[0092] Each of the processing structures 1302 may communicate status data
(e.g. data from the
lift moment indicator 1304 and/or component monitoring systems) about their
respective .hoist
lifting system 100 to a lift monitoring system 1312. The lift monitoring
system 1312 may
comprise a transceiver 1310, a processor 1320, and a human-machine interface
1314. The
human-machine interface 1314 may comprise a display 1316 for presenting at
least a portion of
the status data from the hoist lifting systems 100 and an input device 1318,
such as a touch
screen, keyboard, joystick, mouse, etc. The lift monitoring system 1312 may
execute a lift
planning and monitoring method and system 1250. The human-machine interface
1314 may
receive a margin of safety input from an operator. In some aspects, the human-
machine interface
1314 may limit the margin of safety to within industry standard acceptable
tolerances.
[0093] The lift monitoring system 1312 may provide enhanced quality of data
(e.g. information)
presented on the display 1216 to supervisors. Each processing structure 1302
on the pipe layer
machine 1100 may calculate the stability and loading of each individual
machine 1100. The lift
CA 3012498 2018-07-27
38
=
monitoring system 1312 receives this information, along with the positional
and velocity
information from the sensors and may calculate position adjustments required
to increase or
decrease the loading and/or tipping moment on each pipe layer machine 1100
using the
previously input weight per unit length of the lifted load and/or by
calculating the input weight
based on the spacing and measured lifted load of each pipe layer machine 1100.
The lift
monitoring system 1312 may suggest commands such as boom lift/lower, load hook
lift/lower,
vehicle forward/back position adjustments, positioning closer to/further from
the hoisted load, or
velocity increase/decrease adjustments to vary the amount of load and/or
tipping moment for
each pipe layer machine 1100. For example, the lift monitoring system 1312 may
display live
status data for each hoist lifting system 100 and/or warn of impending
potential problems and
suggest corrective actions. In some aspects, the lift monitoring system 1312
may override
controls of one or more of the hoist lift systems 100 and/or may shut down
lift operation of one
or more of the hoist lift systems 100. In some aspects, one or more hoist lift
systems 100 may be
overridden to hold the load in a stationary position. In some aspects, the
lift monitoring system
1312 may assume control of all hoist lift systems 100 to synchronously lift or
lower a load to a
desired position while monitoring each hoist lift system 100 to ensure none
are overloaded.
[0094] When the hoist lifting systems 100 are operating on level ground, each
may behave
analogously to a two-force member, omitting friction in the pivot 240, with a
resultant force may
be calculated from a luff load cell (not shown), boom angle 220, 222, and a
calculation of a
resulting slung load. Using this equivalent two-force member load and the
material and
geometry of the boom, a structural safety may be calculated as a compressive
load may be
compared to a critical buckling load of the boom 108, and the shear stress in
the pivot pins 240
compared to their maximum allowable stress.
CA 3012498 2018-07-27
39
[0095] On level ground, the force vector, Feq, acts along the boom 108 with an
equal force
vector acting in the opposite direction to the force vector, Feq to maintain
the boom 108 in a
static position. Knowing the measured upper luff force, F
- upperluf f and angle of the boom 108 to
the boom cable, the force vector, Feq may be:
Feq = 2Fupperluf f cos(E)
where the boom strength factor is equal to the critical buckling load of the
boom 108 divided by
Feq.
[0096] When on angled ground, operating on fore-aft slopes may induce bending
moment in the
boom 108 and may lead to unequal loads in the pivot pins. Therefore, the
additional load in the
pins may be given by:
Fzdboom, AP2 = Fzd boom
=
dpins dpins
where the bending load on the tip, Fz, is:
F tan(8)
= ____________________________________________ = F sin(S) =
V(tanA)2 + 1+ (tan 6)2
and dpt =ns is the distance between to pins and dboom is the length of the
boom 108. The stress on
the boom 108 due to the bending moment is more complicated as it is a non-
prismatic beam in
this loading direction, and is calculable using the geometry of the boom
structure.
[0097] Operating on complex ground slopes, the mechanics of the boom 108 may
change as the
mechanics may no longer be analogous to the two-force member. The projection
of a
CA 3012498 2018-07-27
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gravitational vector into the principle planes of the hoist lift system 100
may show that an out-of-
plane component creates a lateral bending moment on the boom tip 102. This
force may act
perpendicular to an axis of the boom pivot 240 and thus does not directly
affect its pivoting. It
may create a bending moment in the boom 108 and thus may create bending
stresses and
potential failure modes not accounted for in the level ground critical
buckling case. An induced
torque may also alter reaction forces in the pivot 240, increasing the load in
one and thus
decreasing the load in the other as they act to oppose this moment.
Accordingly, the shear stress
in the maximally loaded pivot 240 may be significantly higher than would be
caused by a similar
slung load carried on level ground.
[0098] In this aspect, the lift moment indicator 1304 may accurately predict
hoist lifting system
100 tipping mechanics on slopped ground. Further details of the lift moment
indicator 1304 are
provided in in CA 2,974,819 and U.S. Prov. App. No. 62/538,966, both of which
are herein
explicitly incorporated by reference in their entirety. The lift moment
indicator 1304 may
comprise a sensor array for determining a tipping factor of the hoist lifting
system 100 and/or
mobile platform 1102 in real-time. The tipping factor for each hoist lifting
system 100 may be
provided via communication to the lift monitoring system 1312. In some
aspects, the sensor
array may use sensors that are provided on the main body 1102 instead of on
the boom 108. In
this manner, these sensors may be less likely to get damaged during removal,
transport and
reinstallation of the boom 108.
[0099] The sensor array may include a boom winch load pin, a luff
accelerometer, and a boom
winch encoder. Additionally, a vehicle accelerometer may be provided on the
main body 1102
and the lift winch encoder 106 may be provided on the lift winch 104, as
previously described.
The load pin may be pivotally connect the luff block to the main body 1102 to
determine the
CA 3012498 2018-07-27
41
force being applied to the luff block by the boom cable. This force measured
by the load pin
may indicate the force being applied to the distal end 1120 of the boom 108 by
the boom cable
running between the luff block and the boom block. The luff accelerometer may
be positioned
on the luff block and used to measure the position of the luff block and in
particular the angle of
the luff block. This angle of the luff block may indicate approximately the
angle of the boom
cable running between the luff block and the boom block.
101001 The boom winch encoder may be used to more accurately approximate an
angle of an
imaginary line running between the load pin where the luff block is pivotally
connected to the
main body 1102 and the distal end 1120 of the boom 108. The luff accelerometer
may measure
the angle of the luff block. But because of friction between the luff block
and the load pin, slack
in the boom cable as it runs between the luff block and the boom block, etc.,
the luff block may
not always point directly at the distal end 1120 of the boom 108. Instead, the
angle of the luff
block may lag behind the angle of an imaginary line passing between the load
pin and the distal
end 1120 of the boom 108 when the boom 108 is being raised. Therefore, the
luff accelerometer
may tend to indicate an angle that may be slightly less than the actual angle
when the boom 108
is being raised. Additionally, the pivoting of the luff block may also lag
when the boom 108 is
being lowered so that the angle of the luff block being measured by the luff
accelerator may tend
to be measured as greater than the angle of an imaginary line passing between
the load pin and
the distal end 1120 of the boom 108.
101011 The boom winch encoder may be used to adjust the angle of the luff
block determined by
the luff accelerometer. When the boom winch encoder determines that the boom
winch 1112 is
winding and therefore raising the boom 108, the angle measured by the luff
accelerometer may
be adjusted by adding an amount (e.g. a correcting offset) to the measured
angle to accommodate
CA 3012498 2018-07-27
42
for the luff block angle lagging and not pointing directly at the distal end
1120 of the boom 108.
This correcting offset may allow a more accurate approximation of an angle to
the distal end
1120 of the boom 108.
[0102] Conversely, when the boom winch encoder may determine that the boom
winch is
unwinding and therefore lowering the boom 108, the angle measured by the luff
accelerometer
may be adjusted by subtracting the correcting offset from the measured angle
to adjust the
measured angle and get a more accurate approximation of the angle to the
distal end 1120 of the
boom 108.
[0103] The vehicle accelerometer may be used to determine an angle of incline
of the pipe layer
machine 1100 from side-to-side, front-to-back, and/or a combination of these
slopes. For
example, if the pipe layer machine 1100 is positioned on flat ground then the
lateral incline angle
of the pipe layer machine 1100 is 0-degrees and the weight of the pipe layer
machine 1100 will
act directly downwards from the center of gravity of the pipe layer machine
1100 onto the
ground surface supporting the pipe layer machine 1100. However, if the pipe
layer machine
.. 1100 is on a lateral sloping ground surface, depending which way the pipe
layer machine 1100 is
inclined, the incline of the pipe layer machine 1100 may either cause the
righting moment to be
greater than it would be if the pipe layer machine 1100 was on flat ground
while the tipping
moment may be less or conversely may cause the righting moment to be less than
it would if the
pipe layer machine 1100 was on level ground while the tipping moment may be
greater. The
lateral incline of the pipe layer machine 1100 may also affect the position of
the distal end 1120
of the boom 108, because if the pipe layer machine 1100 is tilted, the distal
end 1120 of the
boom 108 may be in a different position than it would be in if the pipe layer
machine 1100 was
on level ground.
CA 3012498 2018-07-27
43
[0104] The front-to-back incline of the pipe layer machine 1100 similarly
affects the righting
moment and the tipping moment. Most tipping factors account only for tipping
about the first
track 1106 of the pipe layer machine 1100, however the use of the sensor array
may allow the
calculation of frontwards and rearwards tipping factors which describe the
likelihood of the pipe
'5 layer machine 1100 to tip over about a tipping fulcrum located at either
the front or rear edge of
the first track 1106 where they contact the ground, respectively.
[0105] The lift winch encoder 106 may be positioned on the lift winch 104 to
determine the
direction of rotation of the lift winch 104 and the distance the hook block
112 has travelled and
the direction of travel.
[0106] To determine the tipping stability of the pipe layer machine 1100, the
sensor array may
be used to measure a number of forces and positions and then this data may be
used to determine
the position of the distal end 1120 of the boom 108, which in turn may be used
to determine the
slung load (the weight of the load suspended from the boom 108). With the
slung load and the
position of the distal end 1120 of the boom 108 determined, the tipping moment
acting on the
pipe layer machine 1100 and the counteracting righting moment may be
determined and used to
determine the tipping stability or "tipping factor" of the pipe layer machine
1100.
[0107] A tipping stability for each pipe layer machine 1100 may be expressed
in many ways.
One way of expressing this tipping stability may be a tipping factor (or
percent tipping), which is
a numerical expression of the tipping stability. In one aspect, a tipping
factor having a value less
than 1 or 100% represents that the machine has not tipped, a value of 1 or
100% represents that
the machine has reached its exact tipping point, and a value greater than 1 or
100% represents
that the machine is tipping over. This tipping factor may be the tipping
moment created by the
CA 3012498 2018-07-27
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load being lifted by the pipe layer machine 1100 divided by the righting
moment which is the
moment created by the weight of the pipe layer machine 1100 with the moment
created by the
boom 108 of the weight subtracted from it. This tipping factor may be
expressed in numerous
ways, including as follows:
TippingMoment
TippingFactor =
PipelayerWeightMoment ¨ BoomWeightMoment
[0108] Or as follows:
TippingMoment + BoomWeightMoment
TippingFactor = ______________________________________________
PipelayerWeightMoment
[0109] Or as follows:
CoGDistanceToTippingFulcrum@CurrentSlope
TippingFactor =
CoGDistanceToTippingFulcrum@ZeroSlope
[0110] Or as follows:
CurrentSlope
TippingFactor = ________________________________________
CalculatedTippingSlope
[0111] Or as follows:
RightingMoment@CurrentSlope
TippingFactor = 1 __________________________________________
RightingMoment@ZeroSlope
[0112] Turning now to FIG. 13, there is provided a process 1400 for lift
planning. The lift
monitoring system 1312 may read environmental data at step 1402. The
environmental data may
comprise ground slopes, ground conditions, travel way, and/or trench
distances. The
CA 3012498 2018-07-27
45
environmental data may be obtained from surveying data stored in a database of
the full 3-
dimensional nature of the work site. The lift monitoring system 1312 may then
receive
equipment data at step 1404. The equipment data may comprise the number of
available pipe
layer machines 1100 and/or a specification for each of the pipe layer machines
1100 and/or hoist
lifting systems 100 (e.g. size, lift capacity, options, etc.). Each different
size of pipe layer
machine 1100 may have characteristics of maximum loads and distances from the
first tipping
fulcrum and front/rear tipping fulcrum, further dependent on the length of the
boom 108 that may
be installed. The tipping fulcrums may also be dependent on which sets of
optional equipment,
such as counterweight assemblies, mechanic platforms, winches, toolboxes, etc.
that are installed
on the pipe layer 1100. These factors may determine the load chart for each
pipe layer machine
1100, further adjusted for any compound ground slopes each pipe layer machine
1100 would be
operating on. Collectively, these specifications and options may comprise the
load-distance
relationship for each machine 1100 located on the ground conditions and trench
distance at every
given position along the load path. The lift monitoring system 1312 may then
read in the load
characteristics at step 1406, such as the total weight, weight per foot,
strength (e.g. maximum
allowable distance between supports). Once the lift monitoring system 1312 has
received or read
in all of the project data (e.g. environmental data, equipment data, and load
characteristics), each
pipe layer machine 1100 may be assigned to an initial location and/or a path
of travel at step
1408.
[0113] Once the lift planning process 1400 has been completed, the assignment
plan may be
transmitted to the processing structure 1302 of each pipe layer machine 1100
and displayed to
the operator on a display (not shown). The lift monitoring system 1312 may
then begin a
monitoring process 1500. The lift monitoring system 1312 may receive
environmental data over
=
CA 3012498 2018-07-27
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its transceiver 1310 from one or more of the processing structures 1302 of
each pipe layer
machine 1100 at step 1502. Each processing structure 1302 may periodically
update the lift
monitoring system 1312 with updated environmental data over the course of the
lift. The lift
monitoring system 1312 may also receive equipment data from the processing
structure 1302 at
step 1504. The equipment data may comprise a current ground slope, position of
the boom 108,
location, present tipping factor, load lifted, and/or any failure states.
Similarly, the equipment
data may be periodically updated by each processing structure 1302 and
transmitted to the lift
monitoring system 1312. The lift monitoring system 1312 may display the lift
data on the
display 1316 where the lift supervisor may monitor the conditions, along with
suggestions
regarding safety and possible corrective actions.
[0114] Periodically, the lift monitoring system 1312 may perform calculations
to determine error
conditions, warnings, and/or suggest corrections to the lift supervisor (as
described above) and/or
operators at step 1508. These errors, warnings, and/or suggested corrections
may be displayed
on the display 1316 for the lift supervisor. In some aspects, the errors,
warnings, and/or
suggested corrections may be transmitted from the lift monitoring system 1312
using its
transceiver 1310 to one or more of the processing structures 1302 of the pipe
layer machines
1100 for display to the operator.
[0115] In some aspects, one or more override commands may be determined by the
lift
monitoring system 1312 and transmitted to the processing structures 1302 of
the pipe layer
machines 1100. The override commands may control the pipe layer machines 1100
to prevent
overloads or instability at step 1510. These commands may include alterations
to the relative
position of the pipe layer machines 1100, increasing or decreasing gaps
between pipe layer
machines 1100, lifting or lowering booms 108, lifting or lowering the load to
transfer more or
CA 3012498 2018-07-27
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less load to each machine 1100. These commands may also lock out an ability of
the operator to
perform some actions if doing so compromises safety, and/or may pass control
over to the lift
supervisor and have the lift supervisor remotely operate (and override the
operator of) one or
more piece of equipment.
[0116] For synchronized events, such as the final laydown of the pipe (or
other load), the lift
,monitoring system 1312 may determine when each of the pipe layer machines
1100 has reached
the appropriate location for laydown. The lift monitoring system 1312 may then
send a laydown
command to the processing structure 1302 of each pipe layer machine 1100 at
step 1512. The
laydown command may comprise a minimum and/or target laydown time, a maximum
laydown
velocity, a trench distance from the travel way, a laydown sequence (e.g.
Machine A to touch
ground first, then Machine B, then C, etc.).
[0117] In some aspects, the lift monitoring system 1312 may comprise a mobile
device, such as
a tablet, smartphone, heads-up display, virtual-reality headset, or augmented-
reality glasses,
where the supervisor may receive control and status data.
[0118] Although some aspects herein describe an example particularly related
to pipe layer
machines 1100, the aspects may equally apply to other types of machinery such
as fixed and/or
mobile cranes, dragline booms, shipboard cranes, elevator hoists, product
skips, overhead cranes,
etc.
[0119] Although some aspects herein measure the rope 120 length and/or speed
using the lift
winch encoder 106, the rope 120 length and/or speed may be measured using a
contact-wheel
placed on the rope 120 where it exits the winch drum 104 or any location along
the rope 120, or
other similar methods.
CA 3012498 2018-07-27
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[0120] In some aspects, the methods described herein may, to some extent,
function using
calculated data to determine simulated data and life predictions in the
absence of direct
measurements of the load in each individual bearing face. In some aspects, the
individual sheave
loading measurements may be provided by sensors such as a plurality of
conventional single-
channel load pins, sheave bore button load cells, sheave support plate strain
gauges, or other
sensors providing similar data.
[0121] According to any or all aspects, any data from the measurements and/or
the calculations
may be saved to a long term storage device. The measurement and/or calculation
data may be
cross-referenced against an electronic log of physical/visual inspections and
may provide
.. load/usage data to underpin the results of the physical/visual inspections.
This type of data
logging system may assist in building an understanding of the causes of
premature failures.
[0122] The aspect describe herein are considered as illustrative only. The
aspects may be
combined in any and all combinations as would be understood by one of skill in
the art. Further,
since numerous changes and modifications will readily occur to those skilled
in the art, it is not
desired to limit the invention to the exact construction and operation shown
and described, and
accordingly, all such suitable changes or modifications in structure or
operation which may be
resorted to are intended to fall within the scope of the claimed invention.
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