Note: Descriptions are shown in the official language in which they were submitted.
NUT GAP MONITORING SYSTEM
Summary
In accordance with some embodiments, a rotating core coupled to a nut and
traveler. The nut separated from a traveler by a nut gap monitored by at least
one
sensor continuously extending through the nut.
Other embodiments have a nut and a traveler each positioned on a rotating
core. The nut separated from a traveler by a nut gap that is monitored by a
first sensor
and a second sensor with each sensor continuously extending through the nut.
Operation of a lifting column, in some embodiments, involves positioning a
traveler and nut on a core with the nut separated from the traveler by a nut
gap. The
core is rotated to vertically displace the traveler and nut and a nut gap
distance is
measured with a sensor that continuously extends through the nut to access the
nut
gap.
Brief Description of the Drawings
FIG. 1 is a block representation of an example maintenance system in which
various embodiments can be practiced.
FIG. 2 depicts a block representation of an example drop table system arranged
in accordance with various embodiments.
FIGS. 3A & 3B represents portions of an example drop table capable of being
used in the systems of FIGS. 1 & 2.
FIG. 4 displays portions of an example lifting column arranged in accordance
with assorted embodiments.
FIGS. 5A & 5B respectively depict portions of an example lifting column
configured and operated in accordance with some embodiments.
FIG. 6 is an example nut gap monitoring routine that may be executed with
assorted embodiments of FIGS. 1-5B.
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Detailed Description
Various embodiments of this disclosure generally relate to a moving assembly
with operation optimized by a nut gap system that accurately monitors
operating
parameters.
Advancements in mechanization have provided equipment that are larger,
heavier, and more capable than predecessors. The sophistication of machinery
can
correspond with increased volumes of maintenance that are needed to provide
the
equipment's capabilities. Some maintenance can involve the lifting, or
lowering, of
relatively heavy equipment, or components removed from the equipment. Such
lifting
can be conducted with one or more lifting assemblies that utilize mechanical,
hydraulic, and/or pneumatic means to articulate the position of attached
equipment.
While the moving assemblies, such as lifting columns, may be capable of
safely handling small-scale equipment can be relatively simple, the vertical
articulation of heavy machinery, such as equipment weighing one ton or more,
can
involve complex and/or cumbersome. For example, a drop table capable of
raising and
lowering vehicle components weighing fifty tons can employ multiple separate
lifting
assemblies acting in unison. Hence, where heavy loads and/or long vertical
distances
are to traversed, lifting assemblies are relied upon for accurate, consistent,
and reliable
operation in order to protect the load being moved as well as the safety of
personnel
and equipment nearby.
Accordingly, a moving assembly can be configured in accordance with some
embodiments with a nut gap monitoring system that provides precise
measurements
that convey the quality, accuracy, and reliability of lifting operations. The
ability to
efficiently monitor the distance between a nut and a traveler in real-time
allows a user
to discern if operational degradation is occurring, which allows proactive
actions to be
taken to prevent operational errors and equipment failures.
Turning to the drawings, FIG. 1 depicts a block representation of an example
maintenance system 100 in which various embodiments can be practiced. The
system
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100 can be configured to service any type, and size, of machinery, such as a
vehicle
102. It is contemplated that more than one vehicle 102 can concurrently be
accessed
and serviced, but such arrangement is not required or limiting.
Although assorted maintenance can be facilitated without physically moving
the machinery 102, such as engine tuning or joint greasing, other maintenance
requires
the separation of one or more components from the vehicle 102. Such separation
can
be conducted either by lifting the machinery 102 while a component remains
stationary or by lowering the component while the machineryl 02 remains
stationary.
Due to the significant weight and overall size of some machinery 102, such as
a
locomotive engine or railcar, the maintenance system 100 is directed to moving
a
component vertically, as represented by arrow 104, with a lifting mechanism
106
while the remainder of the machinery 102 remains stationary.
The lifting mechanism 106 can consist of at least a motor 108, or engine, that
allows one or more actuators 110 to physically engage and move vehicle
component.
A local controller 112 can direct motor 108 and actuator 110 operation and may
be
complemented with one or more manual inputs, such as a switch, button, or
graphical
user interface (GUI), that allow customized movement of the machinery
component.
The local controller 112 can conduct a predetermined lifting protocol that
dictates the
assorted forces utilized by the motor 108 and actuator 110 to efficiently and
safely
conduct vertical component displacement.
In accordance with some embodiments, the lifting mechanism 106 can be
characterized as a drop table onto which the machinery 102 moves to position a
component in place to enable component removal, and subsequent installation.
FIG. 2
depicts a block representation of an example lifting system 120 arranged to
provide
maintenance operations for machinery 102. A lifting mechanism 106 can consist
of
one or more motors 108, actuators 110, and controllers 112 that are utilized
to engage
and secure a machinery component 122, such as a wheel, suspension, engine, or
body,
throughout a range of vertical motion 104.
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Depending on the position and size of the component 122, the lifting
mechanism 106 can vertically manipulate the component 122 itself or the
machinery
102 as a whole to allow efficient access, removal, and subsequent installation
of the
component 122 to be serviced. That is, the lifting mechanism 106 can be
utilized to
separate a component 122 from machinery 102 by keeping the component 122
stationary while vertically moving the rest of the machinery 102 or by keeping
the
machinery 102 stationary while vertically moving the component 122 by itself.
It is contemplated that the lifting mechanism 106 can consist of one or more
lifting columns 124 that operate collectively to vertically displace a
component 122. In
some embodiments, multiple separate lifting columns 124 each raise a platform
126,
as shown in FIG. 2. That is, lifting columns 124 that are physically separated
can be
concurrently activated to apply force on a platform 126 that physically
supports the
component 122. Such unified lifting column 124 and platform 126 can provide
consistent operation over time as deviations in operating characteristics,
such as lifting
speed and precision, are mitigated by the platform 126 that physically brings
the
respective lifting columns 124 into similar operating characteristics.
However, the use
of a unifying platform 126 can make the lifting mechanism 106 rather large and
physically restrictive to machinery 102 and/or components 122 of certain sizes
and
shapes.
Other embodiments configure the lifting mechanism 106 of multiple separate
lifting columns 124 that each contact different portions of a component 122
via
independent protrusions 128. The use of independent lifting columns 124 can
provide
increased physical compatibility with diverse machinery 102 and/or component
122
shapes and sized. In yet, independent lifting columns 124 can be more
susceptible to
component 124 instability during lifting operations as a result of deviations
in
operating characteristics for the respective columns 124. Such independent
lifting
column 124 configuration also suffers from increased complexity compared to
using a
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unifying platform 126 due to the coordination of the respective column's 124
operation to provide secure component 122 movement.
It is contemplated that a lifting column 124 can be secured to a base 130,
such
as a floor, foundation, or frame. A base 130 can be constructed to be
permanently
stationary or move upon activation to relocate the collective lifting columns
124. The
rigid connection of each lifting column 124 to a base 130 can provide
increased
strength to the lifting mechanism 106, but can limit the operational
flexibility of the
system 120. Conversely, the respective lifting columns 124 can have transport
assemblies 132, such as a suspension, wheels, or tracks, that allow a column
124 to
move relative to a base 130 via manual or automated manipulation.
In accordance with various embodiments, multiple lifting columns 124 can be
mounted to a base 130 that can provide vertical 104 and horizontal 134
movement of
relatively large loads, such as 50 tons or more. Such lifting column 124
configuration
can be generally characterized as a drop table, which is depicted in the
lifting system
140 of FIGS. 3A & 3B. The top view of FIG. 3A displays a platform 126 disposed
between and physically attached to multiple lifting columns 124. As directed
by a
local controller 112, one or more lifting motors 142, or engines, can
articulate aspects
of the respective columns 124 to move the platform 126 in the vertical
direction 104.
The controller 112 may further direct one or more transverse motors 144, or
engines,
to activate a drive line 146 and move the platform 126 along the horizontal
direction
134.
It is contemplated that one or more lifting columns 124 are physically
separated from the platform 126, but such configuration would necessitate
individual
motors 142/144 for each column 124 along with complex spatial sensing and
coordination to ensure a load 148 is securely lifted and moved. Instead, the
platform
126 physically unifies the respective lifting columns 124 and provides a
foundation
onto which the load 148 can rest and provide a consistent center of gravity
throughout
lifting 104 and horizontal 134 movement activities.
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FIG. 3B displays side view and an example physical layout of the lifting
system 140 where a base 130 remains stationary while the platform 126 is
vertically
translated. The base 130 provides a secure foundation for the various motors
142/144
and associated transmission to the respective lifting columns 124. The base
130 further
anchors the drive line 146 and number of constituent rollers 150, which can be
wheels,
castors, trucks, or other assembly utilizing a bearing. During normal
operation, the
assorted lifting columns 124 provide uniform platform 126 lifting and
lowering.
However, the fact that the multiple lifting columns 124 can independently
experience failures increases the operational risk of less than all of the
columns 124
experiencing an error. When a lifting column 124 experiences a failure while
other
columns 124 continue to operate, the platform 126 can become unstable, as
illustrated
by segmented platform 152, and the very heavy load 148 can be at risk of
damage
and/or damaging the lifting system 140 as well as nearby equipment and users.
Hence,
the use of independent lifting motors 142, or independent lifting columns 124
separate
from a platform 126, can be particularly dangerous. Furthermore, independent
lifting
columns 124 provide less physical space for motors 142 and limit the available
motor
size and power that can be safely handled by a column 124, which reduces the
efficiency and safety of lifting heavy loads 148 safely, such as over 10 tons.
In contrast to independent lifting columns 124 having independent lifting
motors 142, it is contemplated that a single motor can be employed to power
the
respective columns 124 collectively. While the base 130 could provide enough
space
and rigidity to handle a single motor/engine 142, the failure rates and
operational
longevity of a motor/engine 142 capable of lifting a load 128 weighing tens of
tons
can involve increased service times and frequency that can be prohibitive in
terms of
lifting system 140 operational efficiency. In addition, it is noted that large
parasitic
energy losses can be experienced through transmission that translates the
power output
of a single motor/engine 142 to four separate lifting columns 124.
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Accordingly, various embodiments employ a lifting motor 142 to power two
separate lifting columns 124 that are unified by a single platform that is
vertically
manipulated by the collective operation of the lifting columns 124 and dual
drive
motors 142. The combination of two lifting motors 142 to power four columns
124
provides an enhanced motor efficiency via relatively simple transmissions,
lower
service times/frequency, and relatively simple motor 142 coordination compared
to
independent columns 124 or a single motor powering four columns 124.
FIG. 4 depicts portions of an example lifting column 160 configured in
accordance with some embodiments to provide efficient and safe lifting
operations as
part of a lifting system. It is noted that the lifting column 160 may operate
alone, or in
concert with one or more lifting columns 160 to vertically manipulate a load
with, or
without, a platform extending between columns 160. Through bidirectional
activation
of at least one column 160, a physically attached load 148 can have vertical
movement
104 safely and reliably with minimal load motion and/or vibration.
The operation and physical configuration of a lifting columns 160 is not
limited, but can involve a rotating core 162 positioned within a housing 164
that can
be arranged to prevent debris and other interference from altering the
translation of
mechanical energy from a transmission 166 to a traveler 168 and an attached
load 148
via supporting arm 170, or platform. While the traveler 168 can be the lone
component
that traverses the core 162 in response to core rotation, various embodiments
employ
one or more safety nuts 172 that are also vertically manipulated by core
rotation. The
inclusion of a safety nut 172 ensures that any failure in the traveler 168,
such as
stripped threads, cracks, or cross-threading, results in minimal vertical
displacement of
the attached load 148 as the arm 170 will fall only into contact with the nut
172.
It is contemplated that the nut 172 is positioned in contact with the traveler
168
so that each component concurrently moves about the core 162 as a unitary
assembly.
However, such unitary configuration can result in inadvertent friction, heat,
and stress
that jeopardizes the performance, reliability, and safety of the core 162 and
lifting
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column 160 as a whole. For instance, the combination of traveler 168 and nut
172 can
place undue forces on a single thread or portion of the core 162 when heavy
loads 148
(> 10 tons) are vertically manipulated. Thus, a safety nut 172 is deliberately
separated
from the traveler 168 in some embodiments by a nut gap 174 to provide safety
from
traveler 168 failure without placing excessive force on the core 168,
transmission 166,
or downstream motor 142.
Although the mechanical configuration of the traveler 168 and nut 172 on the
core 162 can be operated at will and manually inspected at any time, it is
noted that
operational defects and degraded performance may occur while the core 162 is
rotating and the traveler/nut are moving, which is dangerous to manually
inspect.
Hence, one or more sensors 176 can be positioned inside, or outside, the
housing 164
to monitor one or more operational characteristics of the lifting column 160
without
any danger to a user.
Various embodiments can utilize any number of sensors 176 of one or more
type to detect operational conditions associated with traveler 168 and nut 172
vertical
manipulation. As a non-limiting example, acoustic, optical, mechanical, and
environmental sensors can be placed throughout the housing 164 to measure the
operating parameters associated with lifting, and lowering, such a
temperature,
humidity, moisture content, rotational speed, distance from the top of the
core 162,
distance to the bottom of the core 162, stress, tension, cracks, plastic
deformation, and
dimensions of one or more threads of the core 162.
With the nearly unlimited sensor 176 configuration possibilities for a lifting
column 160, operation can be closely monitored and collected data can be used
to alter
core 162 operation. For example, core 162 rotation speed and/or scheduled
service
actions that can proactively, or reactively, altered to ensure safe, reliable,
and
consistent future lifting column 160 operation. It is noted that the ability
to accurately
and reliably measure assorted dimensions and distances within the housing 164
is
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critical to the ability to monitor current operational conditions as well as
adjust
operating parameters to optimize future operation.
One measurement that would optimize the sensing of lifting column 160
dimensions and operation is the nut gap distance 178between the nut 172 and
traveler
168. However, the typically small nut gap 174 (< 1 inch) is difficult to
accurately
sense. That is, a small nut gap 174 distance, which may be .25 inches or less,
creates
difficulties in positioning a sensor 176 within, or proximal to, the nut gap
174 to
accurately provide real-time operational measurements, particularly with the
heat,
stress, and presence of grease in the nut gap 174 during operation.
Accordingly, various embodiments are directed to a nut gap monitoring system
that utilizes one or more sensors 176 to accurately measure the nut gap 174
during
operation. FIGS. 5A & 5B respectively depict portions of an example lifting
column
190 configured in accordance with some embodiments to provide optimized
operation
over time and despite the presence of operational degradation, errors, and/or
failures
detected by at least one nut gap system. The side view line representation of
FIG. 5A
illustrates how a traveler 192 is separated from a nut 194 on a rotating core
162 by a
nut gap distance 178, such as .1-1 inch.
The traveler 192 can be constructed with a variety of different sizes, shapes,
and materials that are conducive to cyclic physical loading of heavy loads.
For
instance, the traveler 192 may consist of a single material, such as steel,
tungsten,
polymer, or titanium, or may be a lamination of multiple different materials
that can
provide consistent strength and deformation characteristics despite extreme
physical
stress, heat, and vibration. Regardless the material composition, various
embodiments
configure the traveler 192 with a top body 196 that has a larger relative
diameter to
support an arm or platform and a bottom body 198 that has a smaller relative
diameter.
With the nut gap 174 being small, a nut gap sensor 200 is arranged to extend
through the nut 194 with at least a pin 202 that can physically contact a
bottom surface
204 of the traveler 192 to allow a monitoring unit 206 determine the nut gap
distance
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178 between the traveler 192 and nut 194. The pin 202 can continuously extend
within
a conduit 208 that allows for smooth pin 202 movement and precise accuracy for
unit
206 measurements. It is noted that the use of the pin 202 brings nut gap 174
measurements through the nut 194 and away from the nut gap 174 to a space that
can
accommodate the size and electrical connections of the monitoring unit 206.
While pin 202 movement can provide quick, accurate mechanical readings of
the nut gap distance 178, some embodiments utilize non-mechanical types of
sensors
176 in association with the conduit 208 that continuously extends through the
nut 194.
As a non-limiting example, the conduit 208 can be utilized for wires to
connect the
monitoring unit 206 to an optical or acoustic detector 210 positioned in, or
immediately proximal to, the nut gap 174, which may or may not physically
contact
the bottom surface 204 of the traveler 192. It is contemplated that a
mechanical sensor
200 utilizing a pin 202 can be employed in combination with another non-
mechanical
sensor extending through the nut 194 that utilizes a conduit 208 for
electrical wiring
instead of a moving pin 202.
FIG. 5B illustrates a perspective view line representation of the traveler 192
and nut 194 without the core 162 to show how threads 212 can be provided by
the nut
194 to engage matching threads of a core 162. It is to be understood that the
threads
212 present in the nut 194 can also be present throughout the portions of the
traveler
192 that contact the core 162. The threads 212 of the nut 194 and traveler 192
may
match in some aspects, such as thread pitch and thread depth, and may also be
dissimilar, such as the addition of safety thread geometry in the nut 194 that
is not
present in the traveler 192.
The nut 194 may be free of any direct physical contact with the traveler 192,
which coincides with a wider range of operational characteristics determining
the nut
gap distance 178. However, the nut 194 may alternatively be directly mounted
to the
traveler 192 via one or more fasteners extending through nut apertures 214 and
into
the traveler 192. The addition of direct fasteners, in addition to the conduit
208 that
CA 3059397 2019-10-21
extends through the nut 192, can narrow the causes of nut gap distance 178
deviation
and allow nut gap sensing to be more directly tied to thread degradation in
the core
162 and traveler 194, which improves the ability to discern proactive and
reactive
actions that can optimize current and future lifting operations.
It is contemplated, but not required, that the traveler 194 is physically
attached
to an arm or platform. Such direct physical attachment can be facilitated with
fasteners
extending through traveler apertures 216 and into an arm/platform, as shown in
FIG.
4. The operation of the traveler 192 to provide vertical manipulation of a
load can be
aided with grease or other lubricant, which can be pumped into the traveler
194 via
one or more fittings 218 that provide lubrication to the physical interface
between the
core 162 and the threads and inner sidewalls of the traveler 192.
Through the accurate, real-time measurement of a nut gap 174 by one or more
sensors 200, minute deviations in operation can be detected and correlated to
the
traveler or the core, which allows for reactive and proactive actions to be
taken to
modify the operational and/or structural parameters of a lifting column. An
example
nut gap monitoring routine 230 is displayed in FIG. 6 that can be carried out
with the
assorted embodiments of FIGS. 1-5B to provide optimal vertical manipulation of
loads
over time. The routine 230 can begin with one or more lifting columns being
implemented in a machinery maintenance system that can at least vertically
move a
heavy load, such as 50 tons, with a lifting mechanism.
Step 232 positions a load onto arms, or a platform, supported by various
lifting
columns of a lifting mechanism. Some embodiments of step 232 provide a drop
table
where four lifting columns are physically connected via a base and a moving
platform.
Physical attachment of the load to the respective lifting columns allows step
234 to
activate one or more motors/engines that power operation of the lifting
columns as a
collective unit. Step 234, in some embodiments, involves activating dual
motors that
each power two lifting columns in unison to lower, or raise, the attached load
a
selected distance.
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During the lifting operations started in step 234, step 236 monitors the nut
gap
distance of at least one lifting column with at least one sensor that extends
through a
safety nut. Such sensor may consist of a pin, electrical wires, or optical
cable
extending from a monitoring unit to the nut gap where measurements are
accurately
taken and reported to a host in real-time. A host may be a user or
programmable
controller configured to log and react to nut gap distance measurements. The
nut gap
distance measuring in step 236 may be continuous, sporadic, or in scheduled
intervals
to convey if a deviation in nut gap distance is experienced.
Decision 238 can operate concurrently, or sequentially, with step 236 to
determine if a nut gap deviation has occurred. If so, a host can conduct one
or more
reactive actions to compensate for the detected deviation in step 240. A
reactive action
may be to slow down lifting operations, speed up lifting operations, pump more
grease
into a traveler, reduce grease pressure into a traveler, or stopping lifting
operations
altogether.
Decision 242 then evaluates the effectiveness of the reactive action(s) by
monitoring nut gap distance, perhaps with greater time resolution than in step
236. If
the lifting operations have improved and no further nut gap deviation is
experienced,
the load is moved into a final position in step 244. However, if nut gap
deviations
remain or have newly occurred, step 246 proceeds to activate motor safe mode
and
report the maintenance system for service. Such safe mode may involve a
deactivated
motor, increased safety locks, or activation of a supplemental lifting
mechanism to
assist in moving the load to a desired height.
While lifting operations can reactively be optimized through the accurate
measuring of a nut gap distance and generation of intelligent actions to
correct, or
mitigate, such deviations, the ability to proactively prevent deviations in
nut gap
distance provides a lifting column with long-term reliability and safety. The
detection
of actual nut gap deviations in decision 238 may also trigger a host to
predict future
lifting behavior in step 246 based on the detected nut gap deviations. For
example, a
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temporary nut gap distance deviation at a particular location on a rotating
core can be
used to predict future greater deviations as degradation in core threads
persist. As
another non-limiting example, a continuous nut gap deviation can be used to
predict
traveler damage that will increase at a known rate, such as linear or
exponential.
The prediction of one or more future lifting behaviors in step 246 enables
step
248 to generate one or more proactive actions that can be conducted in the
future to
prevent at least one predicted behavior. For instance, grease can be scheduled
to be
removed from a lifting column core, a traveler can be physically reinforced,
or certain
portions of a core can be treated with greater, or lesser, core rotation and
lifting
operation speed. At a convenient time after step 248 generates the proactive
action(s),
such as when a load is not being supported, step 250 then executes one or more
proactive actions generated from step 248.
Through the use of a nut gap monitoring sensor that can accurately detect nut
gap distance in real-time, the operation of a lifting column can be understood
and
improved over time. The ability to identify reactive and proactive actions
from nut gap
measurements that can correct, or at least mitigate, current deviations in
lifting column
operations while preventing other lifting deviations ensures inevitable
operational
deviations do not jeopardize short-term or long-term safety, reliability, or
efficiency.
It is to be understood that even though numerous characteristics of various
embodiments of the present disclosure have been set forth in the foregoing
description,
together with details of the structure and function of various embodiments,
this
detailed description is illustrative only, and changes may be made in detail,
especially
in matters of structure and arrangements of parts within the principles of the
present
technology to the full extent indicated by the broad general meaning of the
terms in
which the appended claims are expressed. For example, the particular elements
may
vary depending on the particular application without departing from the spirit
and
scope of the present disclosure.
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