The top stop challenge - Palfinger — Industry meets Makers

Briefing 2021

Status quo and challenge question

As a global partner for innovative and reliable deck equipment and lifesaving appliances, PALFINGER supplies high-quality products to fulfill standardized and customized demands. Supported worldwide by a network of experienced and skilled specialists, we provide flexible and efficient service solutions. Our portfolio gives a competitive edge for customers in the maritime and offshore industry. PALFINGER provides lifting and handling solutions to all major maritime segments, including Offshore | Oil and Gas, Merchant | Cargo, Passengers | Cruise, Governmental, Wind and Aquaculture.

Marine cranes typically use a winch with a hook and hook block attached at the end of the rope to lift their loads. The hook block is situated directly above the hook to weigh down the hook when there is no load attached. In normal operation the hook block must not collide with the boom tip because this can significantly damage the crane, the winch or the rope itself.

The current solution relies on the hook block touching/lifting a sensor which stops the upward movement. This solution works but has downsides in terms of wear and tear caused by lacquered metal parts hitting each other repeatedly. Over time the lacquer disintegrates, and the steel starts to rust. Additionally, the current solution creates problems with the parking position of the hook where the hook block is slowly moved upwards until it presses hard against the boom tip (Top-stop overridden). This way the hook block and hook are fixed and do not swing. But the chain of the current sensor still moves around, and a part of the sensor is pinched between hook block and boom tip and both is damaging the coating and structure.

The Challenge

We are looking for an innovative, contactless solution to sense the hook and hook block nearing the tip of the crane in order to stop the winch in time.
Proposed solutions need to be able to withstand a very harsh offshore environment (salt, wind, rain, hail, cold, warm, …) without significant maintenance because of poor accessibility.
The hook moves with up to 70 m/min and the time to brake must be considered.
The precision of the stop position is not a primary goal (approx. +/- 200 mm sufficient) provided the collision is avoided.
The sizes of the hook blocks range from 250 mm to 500 mm in diameter.
The boom angle varies from horizontal to 80 deg upwards.
The sensor must be available at least in performance level PLc or better in PLd.
ATEX compatibility of the system would be ideal.
We would be thrilled to find a solution, easy to implement and use. New technologies are more than welcome, given they survive the rough circumstances and are low key to maintain.
The goal for the team during the #IMM2021 development phase is to come up with a first prototype.
Ideally the prototype is based on solid technology research or clear arguments for the choice/suggestion.

Value added

Avoid unnecessary damage on the crane top and potential consequential damages.
Maintain a high level of safety and security for the operator.
Develop a cost-effective solution.

Perspectives

Collaboration with and support from PALFINGER’s innovation team P21st throughout the entire process. Especially from the technology expert and the open innovation team.
Exchange and inputs from the product line Loader-, Marine & Wind Cranes and their team of engineers and experts.
Possibilities for a potential longer-term collaboration are discussed and defined depending on the concrete outcomes and preferences.

Intro videos

#IMM2021 online kick-off invitation from Mario Roither (PALFINGER).

Briefing pitch @ #IMM2021 online kick-off from Christine Spernbauer and Mario Roither (PALFINGER) on April 15th 2021.

Next Steps

Register for the challenge!
Follow up call to get to know each other, gain a better understanding of the challenge and clarify open questions
1. Milestone: Hand in your concept how you would answer to the challenge
Feedback from PALFINGER
Define touch points with PALFINGER’s marine business; regular check-ins or on demand calls throughout the entire IMM process.
2. Milestone: POC (budget ear-marked)
Possibility for an on-site visit in Salzburg or the production site (depending on COVID-19 regulations)
Presentation of the results at the Best of Industry meets Makers event on October 18th

Call to Action

We are looking for makers, creative minds, developers or start-ups with a „pirate mindset”, motivated to develop solutions that can withstand and serve under extreme conditions.

Contact

The main contact persons for the project on the part of PALFINGER are Christine Spernbauer and Stefan Kreppel from the P21st open innovation team. In addition, Mario Roither (P21st technology expert) and Gerolf Schlager (PALFINGER MARINE, Discipline Leader Standards & Systems) will support you with their technical expertise and industry know-how.

About Palfinger

Established in 1932, PALFINGER stands for the most innovative, reliable and cost-effective lifting solutions for use on commercial vehicles, ships and stationary equipment. Innovation and further internationalisation of products, processes and services form, in addition to greater flexibility, are the lived strategic pillars of the corporate strategy. To allow for a prioritization of the challenges and opportunities of digital transformation, this time-tested strategy has been supplemented by a fourth pillar: PALFINGER 21st stands for new core competences, new approaches, new products, services and business models in the digital age. High flexibility and competence in production and a global sales and services network give us a crucial competitive edge and ensure our customers LIFETIME EXCELLENCE.

As a multinational company group with its headquarters in Bergheim near Salzburg, Austria, PALFINGER has more than 30 manufacturing and assembly sites in Europe, in CIS, in North and South America as well as in Asia. With around 5,000 sales and service outlets on five continents PALFINGER is always close to the customer no matter the location. This worldwide presence results in an optimal pre- and after-sales service tailor-made to the needs of each specific market. More than 95 per cent of the products are exported in more than 130 countries worldwide.

More about PALFINGER, PALFINGER MARINE and PALFINGER 21st