LIGHT GRID SYSTEM FOR ROPE MACHINERY

• US 20140157634A1
• Filed: 12/10/2012
• Published: 06/12/2014
• Est. Priority Date: 12/10/2012
• Status: Active Grant

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Fix, Russell A., Onsager, James
• Granted Patent: US 9,194,100 B2
• Time in Patent Office: Days
• US Class Current: 37/396
• CPC Class Codes: B66D 1/50 for maintaining predetermined rope, cable, or chain tension, e.g. in ropes or cables for towing craft, in chains for anchors; Warping or mooring winch-cable tension control
• CPC Class Codes: E02F 3/48 Drag-lines
• CPC Class Codes: E02F 9/2016 Winches winches per se B66D
• CPC Class Codes: E02F 9/264 Sensors and their calibration for indicating the position of the work tool
• CPC Class Codes: E02F 9/268 with failure correction follow-up actions
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

A light grid system for rope machinery is provided. The light grid system includes one or more light grid assemblies, including one or more sensor frames configured to be coupled to one or more post assemblies and configured to mount adjacent to one or more rope drums. The light grid assemblies also include one or more sensors coupled to the sensor frames, at least a first sensor configured to emit one or more light beams, at least a second sensor configured to receive the light beams. The light beams are positionable a predetermined distance away from the ropes, and the light grid assemblies are configured to transmit a signal to a control module when the light beams are obstructed.

Claims

1. A light grid system for rope machinery, the rope machinery including one or more rope drums having a center line, and one or more ropes wrapped around the rope drums, the ropes configured to maneuver a machinery component, the light grid system comprising:

one or more light grid assemblies, comprising;

one or more sensor frames configured to be coupled to one or more post assemblies and configured to mount substantially perpendicular to the center line of one or more rope drums;

one or more sensors coupled to one or more sensor frames, at least a first sensor configured to emit one or more light beams, and at least a second sensor configured to receive one or more light beams;

wherein the light beams are positionable a predetermined distance away from the ropes; and

wherein the light grid assemblies are configured to transmit a signal to a control module associated with the rope machinery when one or more light beams are obstructed.

2. The light grid system of claim 1, the post assemblies further comprising a top post coupled to a bottom post, the top post configured to move up or down relative to the bottom post, raising and lowering the height of the sensors.

3. The light grid system of claim 2, further comprising one or more vertical adjustment points located on the top post and configured to align with one or more vertical mating holes located on the bottom post, and locking hardware configured to mate with the vertical adjustment points and vertical mating holes, locking the top post relative to the bottom post.

4. The light grid system of claim 1, further comprising one or more sensor brackets coupled to the sensors and configured to move left or right relative to the sensor frames, adjusting the sensors horizontally.

5. The light grid system of claim 4, further comprising one or more horizontal mating holes located on the sensor brackets and configured to align with one or more horizontal adjustment points located on the sensor frames, and locking hardware configured to mate with the horizontal adjustment points and horizontal mating holes, locking the sensor brackets relative to the sensor frames.

6. The light grid system of claim 1, wherein the predetermined distance is twice the diameter of the rope.

7. The light grid system of claim 1, wherein the sensor frames are configured to rotate relative to the post, in a plane perpendicular to the post assemblies.

8. The light grid system of claim 7, further comprising one or more removable pins configured to couple the sensor frames and the post assemblies, preventing the sensor frames from rotating relative to the post assemblies.

9. The light grid system of claim 1, wherein the control module is configured to transmit an operator alert upon receiving the signal.

10. The light grid system of claim 1, wherein the operator alert reduces power to the rope machinery.

11. A dragline excavator, comprising:

a bucket assembly;

one or more rope drums having a center line;

one or more ropes wrapped around the rope drums, the ropes configured to maneuver the bucket assembly;

one or more light grid assemblies, comprising;

one or more sensor frames configured to be coupled to one or more post assemblies and mounted substantially perpendicular to the center line of the rope drums;

one or more sensors coupled to one or more sensor frames, at least a first sensor configured to emit one or more light beams, and at least a second sensor configured to receive one or more light beams;

wherein the light beams are positionable a predetermined distance away from the ropes; and

wherein the light grid assemblies are configured to transmit a signal to a control module associated with the dragline excavator when one or more light beams are obstructed.

12. The light grid system of claim 11, the post assemblies further comprising a top post coupled to a bottom post, the top post configured to move up or down relative to the bottom post, raising and lowering the height of the sensors.

13. The light grid system of claim 12, further comprising one or more vertical adjustment points located on the top post and configured to align with one or more vertical mating holes located on the bottom post, and locking hardware configured to mate with the vertical adjustment points and vertical mating holes, locking the top post relative to the bottom post.

14. The light grid system of claim 11, further comprising one or more sensor brackets coupled to the sensors and configured to move left or right relative to the sensor frames, adjusting the sensors horizontally.

15. The light grid system of claim 14, further comprising one or more horizontal mating holes located on the sensor brackets and configured to align with one or more horizontal adjustment points located on the sensor frames, and locking hardware configured to mate with the horizontal adjustment points and horizontal mating holes, locking the sensor brackets relative to the sensor frames.

16. The dragline excavator of claim 11, wherein the sensor frames are configured to rotate relative to the post assemblies, in a plane perpendicular to the center line.

17. The dragline excavator of claim 16, further comprising one or more removable pins configured to couple the sensor frames and the post assemblies, preventing the sensor frames from rotating relative to the post assemblies.

18. The light grid system of claim 11, wherein the control module is configured to transmit an operator alert upon receiving the signal.

19. A method for installing a light grid system for rope machinery, the method comprising:

providing a first set of light grid assemblies having a transmitter configured to emit a plurality of light beams;

providing a second set of light grid assemblies having a receiver configured to receive the plurality of light beams from the transmitter;

positioning the transmitter and the receiver to provide a light grid at a predetermined distance in relation to one or more rope drums; and

providing a control module configured to initiate a response when one or more light beams are obstructed.

20. The method of claim 19, further comprising alerting an operator upon receiving a signal from the control module.