Patent Description:
In various workplace environments, workers, platforms, scaffolding, equipment, products, and other loads are positioned at elevated heights either by placing a load on an elevated work surface and/or by suspending a load from one or more cables for maintaining the load in an elevated position. Examples of such workplace environments include, but are not limited to, large scale assembly facilities, aviation construction and maintenance platforms, building construction and maintenance platforms, ladders, and the like. Fall protection systems are used in such workplace environments to protect the loads and the surrounding structures and personnel when the loads accidentally fall from their elevated positions.

Existing fall protection systems are often implemented as self-retracting lanyards (also called "SRL", self-retracting lifelines, fall arrestors or load arrestors) that are configured to limit a vertical distance a load can fall from an elevated position. Self-retracting lanyards include a lanyard or lifeline (referred to herein as a lifeline) wrapped around a spring-biased spool or reel and a brake inside a housing unit. A distal end of the lifeline has a coupling device, such as a carabiner, for coupling the self-retracting lanyard to a load or to an independent anchor point of a structure above the load's elevated position. The housing unit has a connector for attaching the housing unit to the independent anchor point or the load. The spring-biased spool is biased to automatically rotate the spool in a direction that retracts the lifeline into the housing unit and around the spool when the load is not applying an outward force to the lifeline.

When the load applies a pulling force to the lifeline of the self-retracting lanyard, the lifeline extends out of the housing unit, and the spring-biased spool provides a slight tension on the lifeline in an opposite direction, so the minimum amount of lifeline required is exposed at any given time. If the load falls from an elevated position, a greater pulling force will be applied, and the lifeline will rapidly extend further out of the housing unit causing the spring-biased spool to rotate faster in the direction opposite the bias. The brake in the housing unit is activated when the rotational speed of the spring-biased spool reaches a threshold brake speed in the direction opposite the spring bias, thereby arresting the spool's rotation, arresting further extension of the lifeline, and arresting the load from falling further.

Such systems often require the load to move through a minimum vertical deceleration distance after a fall before the arresting action of the brake occurs. If the independent anchor point for the self-retracting lanyard is not directly above the load's center of gravity when the load falls from the elevated position, i.e., the lifeline is at an angle greater than <NUM>° relative to the fall direction of the load, the load will move in a horizontal direction in addition to the vertical deceleration distance like a pendulum, otherwise known as swing, which may cause damage or injury to the load or to the surrounding structures or personnel.

One solution to minimize swing has been to attach a self-retracting lanyard to a trolley which is attached to and moves along a solid structure, such as an I-beam, above the load. However, this solution requires additional structure, which may not be available, appropriate, or cost effective, and diligence from a user of the system to move the trolley so it remains directly above the load's center of gravity. This solution also limits travel to one direction and only as far as the trolley can extend.

Another solution is to use multiple self-retracting lanyards anchored so that the load's center of gravity is between the self-retracting lanyards. However, this type of system is not effective because it does not guarantee that more than one of the self-retracting lanyards will engage during a fall. When the brake in one of the self-retracting lanyards engages, the momentum from the fall is stopped and the brakes in the remaining self-retracting lanyards will not sense the fall. Thus, the remaining self-retracting lanyards will not engage. With one of the multiple self-retracting lanyards arresting a fall while other lifelines remain free to extend, the load will move in a horizontal direction; thus, the swing risk is still present. Further, this type of system should maintain commonality between the multiple self-retracting lanyards (i.e., the angle between the lifeline and the fall direction needs to be equal for all the self-retracting lanyards and all the self-retracting lanyards should be of the same make and quality). Therefore, anchoring options and movement of the load are also limited.

<CIT>, in accordance with its abstract, states: A retractable lanyard mechanism that includes a housing, a frame and a drum that is rotatably supported from the frame mounted within the housing. The drum includes a pair of spaced apart disks, the spaced apart disks being attached to opposite ends of a spool, each spaced apart disk having a perimeter including at least one sperrad. A locking bar that is pivotally mounted from the frame, the locking bar extending from the frame at a location next the perimeter of each of the spaced apart disks and is movable from an up position wherein the locking bar does not engage the sperrad on each of the spaced apart disks, and a down position wherein the locking bar engages the sperrad on each of the disks, the locking bar mechanism being movable from the up position to the down position by a momentum pawl mechanism that is mounted from the frame, so that rotation of both of the spaced apart disks is stopped by moving the locking bar to the down position in response to a level of momentum achieved by the momentum pawl mechanism.

<CIT>, in accordance with its abstract, states: A self-retracting lifeline includes a common, central brake hub having teeth on opposing sides and a lifeline assembly on each side of the brake hub. The lifeline assemblies include centrifugal clutch assemblies with pawls. The pawls are configured and arranged to engage the teeth of the brake hub to stop the lifeline assemblies when there is a sudden acceleration or a high rate of speed at which the lifeline assemblies turn to pay-out lifeline which causes the pawls to pivot and engage the teeth. The self-retracting lifeline may be operatively connected to a safety harness with a connector interconnecting the bottom of the self-retracting lifeline and the straps of the safety harness proximate a dorsal pad assembly and straps interconnecting the housing of the self-retracting lifeline and the straps of the safety harness above the dorsal pad assembly. The lifelines of the self-retracting lifeline exit the housing proximate the top.

<CIT>, in accordance with its abstract, states: A safety apparatus is disclosed. The device is used to prevent falls during work at heights or in areas where the operator may loose support from below. The apparatus has a first housing supporting two spools coaxially mounted and independently rotatable. A support line extends from one spool to the other spool via a second support assembly and an operator support connection. In use each support is attached to separate anchor sites either side of a work area with the support line connecting between. The first housing also contains a locking device which when operated locks the two spools relative to each other so they no longer rotate independently. The locking device is maintained in a locked condition, locking the spools relative to each other, when a load of predetermined value, such as the weight of a fallen operator, is exerted upon the support line. When the load is removed the locking device is released and two spools can once again rotate independently.

Systems and methods are disclosed herein and defined in the claims that provide an improved approach to fall protection with multiple self-retracting lanyards that share a single braking system and form a fall protection system. The multiple self-retracting lanyards have respective lifelines wound on respective spools (or reels) which operate independently when a load, such as a worker, platform, scaffolding, equipment, or product is maintained at an elevated position on an elevated work surface and/or by suspending the load from one or more cables or other devices. That is, each of the lifelines in the multiple self-retracting lanyards can be extended at different speeds, lengths, and times, and be automatically retracted at different times depending on the forces the load applies to each of the lifelines during use.

When a load falls from the elevated position, however, the single braking system senses or reacts when a rotational speed of any one of the respective spools in the multiple self-retracting lanyards increases to a threshold brake speed, upon which the single braking system is engaged to simultaneously arrest rotation of all the spools and extension of all the lifelines of the multiple self-retracting lanyards. All the lifelines are taut because of the weight of the load when it is hanging by the arrested lifelines and do not permit the load to move in a horizontal direction. Thus, the risk of a swing hazard is eliminated regardless of whether the self-retracting lanyards are evenly spaced apart (i.e., the lifeline to fall direction angle need not be equal for all self-retracting lanyards) or placed directly over the load's center of gravity.

In one aspect, a fall protection system for a load in an elevated position is provided. The fall protection system includes at least two self-retracting lanyards configured to be removably coupled to the load and to an independent anchor point preferably above the load. The at least two self-retracting lanyards are associated with a single braking system that arrests movement of the at least two self-retracting lanyards when a speed of any one of the at least two self-retracting lanyards has increased to a threshold brake speed. The at least two self-retracting lanyards include respective lifelines wound on respective spools, and the respective spools are independently rotatable around a central axle of the fall protection system. The single braking system is operable to arrest movement of the respective spools when the single braking system mechanically senses that a rotational speed of any one of the respective spools has increased to the threshold brake speed.

The single braking system includes at least two brake assemblies respectively associated with the respective spools of the at least two self-retracting lanyards and rotatable around the central axle of the fall protection system. The brake assemblies rotate at a speed equal to the rotational speed of the fastest rotating one of the respective spools. In the single braking system, at least one pawl is movable by centrifugal force acting against a spring force and positioned to engage an end brake gear to arrest movement of the at least two brake assemblies and the respective spools when at least one of the respective spools has reached the threshold brake speed. In certain aspects of the fall protection system, the single braking system employs at least two pawls that are radially positioned around the central axle at unequal radial angles or unequal radial positions and are engageable with the end brake gear. In other aspects, the single braking system employs one or more pawls that engage a gear formed by an outer edge of a recessed space in a side of the respective spools and when more than one of these pawls is employed, the pawls are radially positioned around the central axle at unequal radial angles or unequal radial positions.

In another aspect, a braking system is disclosed for simultaneously arresting movement of at least two self-retracting lanyards. The braking system includes a first spool brake assembly that rotates around a central axle and is positioned to react with a first gear formed by an outer edge of a recessed space in a side of a first spool of a first self-retracting lanyard. A second spool brake assembly is positioned to rotate around the central axle and react with a second gear formed by an outer edge of a recessed space in a side of a second spool of a second self-retracting lanyard. The second spool brake assembly is connected to the first spool brake assembly through a torsion shaft that is also rotatable around the central axle. An end brake assembly is positioned to rotate around the central axle and is coupled to the first spool brake assembly such that the first spool brake assembly, the torsion shaft, the second spool brake assembly, and the end brake assembly rotate around the central axle at equal speeds. The braking system has at least one pawl that is movable by centrifugal force acting against a spring force to engage an end brake gear to arrest movement of the end brake assembly, the first spool brake assembly, the second spool brake assembly, the first spool, and the second spool when a first rotational speed of the first spool or a second rotational speed of the second spool reaches a threshold brake speed. In certain aspects of the braking system, two or more pawls are radially positioned around the central axle at unequal radial positions and/or unequal radial angles to engage the end brake gear.

In another aspect, a method for protecting a load when falling from an elevated position is disclosed. In the method, at least two self-retracting lanyards are removably coupled to the load and the method includes operating the self-retracting lanyards independently when the load is maintained in the elevated position. The method further includes mechanically sensing when a speed of any one of the at least two self-retracting lanyards has increased to a threshold brake speed; and when it is sensed that the speed of any one of the at least two self-retracting lanyards has increased to the threshold brake, engaging a single braking system associated with the at least two self-retracting lanyards to arrest movement of the at least two self-retracting lanyards.

The at least two self-retracting lanyards are configured with respective lifelines wound on respective spools that are configured to rotate independently of each other. In the method, engaging the single braking system includes engaging a gear to arrest movement of the respective spools when mechanically sensing that the rotational speed of any of the respective spools associated with the self-retracting lanyards has increased to the threshold brake speed. The method also includes deploying at least one pawl that is movable by centrifugal force acting against a spring force when the rotational speed of any of the respective spools has increased to the threshold brake speed. In certain aspects of the method, the at least one pawl engages an end brake gear of a brake assembly to arrest movement of the single braking system and the respective spools.

In another aspect, a method of making a fall protection system includes disposing at least two self-retracting lanyards in a housing of the fall protection system and associating the at least two self-retracting lanyards with a single braking system in the housing that arrests movement of the at least two self-retracting lanyards in the event of an increased speed of any one of the at least two self-retracting lanyards to the threshold brake speed.

The disclosed systems and methods eliminate the risk of a swing hazard by ensuring that movement of all lifelines in the self-retracting lanyards is simultaneously arrested by the single braking system, and the systems and methods provide continuous and unrestrained safe travel along a two-dimensional or three-dimensional work area or length. No additional support structure is required, such as a trolley system, and there is no need to maintain commonality of the multiple self-retracting lanyards. The disclosed systems and methods permit many possible anchoring configurations and provide a safe way for a load to "leap-frog", i.e., the action of a load passing between one set of self-retracting lanyard anchor points to another set while maintaining active fall protection. This allows for safe extended work areas when limited by anchoring height restrictions, lifeline length, and other structural limitations.

The foregoing features, functions, and advantages of the disclosed systems and methods, as well as other objects, features, functions, and advantages of the disclosed systems and methods can be achieved independently in various examples of the disclosure or may be combined in yet other examples further details of which can be seen with reference to the following detailed description and drawings.

Various implementations of the disclosure will be hereinafter described with reference to drawings for the purpose of illustrating the above-described and other aspects. None of the drawings briefly described in this section are drawn to scale.

Reference will hereinafter be made to the drawings in which similar elements in different drawings bear the same reference numerals. Where reference is made in any one or more of the accompanying drawings to steps and/or features, which have the same reference numerals, those steps and/or features have, for the purposes of this description, the same function(s) or operator(s), unless the contrary intention is apparent.

Illustrative implementations of fall protection systems and methods are described in some detail below. A person skilled in the art will appreciate that in the development of an actual implementation of the disclosed systems and methods, numerous implementation-specific decisions could be made to achieve a developer's specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. It will be appreciated that such a development effort might be complex and time-consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure. Moreover, the disclosed systems and methods can be used or readily adapted for use in any industry and in any work environment where falls are an inherent risk.

<FIG> illustrates a fall protection system <NUM> in an assembled form having two lifelines <NUM> that extend through one or more openings <NUM> in a bottom part of a housing <NUM>. The lifelines <NUM> may be implemented as a flexible line of rope, wire rope, or a flat strap having a distal end <NUM> configured to be coupled to a coupling device <NUM> such as a carabiner, which can be removably coupled to a load. The distal end <NUM> of the lifelines <NUM> may be formed into a loop or be connected to an O-ring, D-ring or similar type of device that can securely hold the coupling device <NUM>. The housing <NUM> includes a center body <NUM> having two opposing open sides and two end plates <NUM> to close the open sides. An anchor <NUM> is positioned on an exterior surface of a top part of the center body <NUM> (opposite the openings <NUM> for the lifelines <NUM> on a bottom part of the center body <NUM>). The anchor <NUM> is connected to the center body <NUM> of the housing <NUM> with a static, non-movable connection or with a movable connection, such as with a hinge pin <NUM> that permits the anchor <NUM> to rotate as shown in <FIG>. It will be apparent to a person of ordinary skill in the art using this disclosure as a reference that the number of lifelines <NUM> in the fall protection system <NUM>, as well as the size and form of the housing, can be readily adapted for different applications.

<FIG> illustrates one exemplary use of the fall protection system <NUM> for protecting a load <NUM> in an elevated position <NUM>. In this example, the load <NUM> is a person or worker, but the fall protection system <NUM> can be used to protect any type of load <NUM> that is placed in an elevated position <NUM> at a height above the ground. For example, the load <NUM> may be a worker, platform, scaffolding, railing system, equipment, or product, such as the skin of an aircraft fuselage, that is maintained in an elevated position <NUM>. The load <NUM> may be positioned on an elevated platform <NUM> in the elevated position <NUM> (such as the worker shown in <FIG>) or instead of a worker the load <NUM> may be an elevated platform <NUM> on which a worker is standing or a piece of equipment suspended by cables or other types of suspension devices in the elevated position <NUM> (such as heavy equipment that needs to be lifted and moved into place for installation or maintenance).

The lifelines <NUM> of the fall protection system <NUM> are removably coupled to the load <NUM> through the coupling device <NUM>. The load <NUM> may have a harness <NUM> with one or more harness connectors <NUM> positioned on the sides and/or top or front of the load <NUM> to facilitate coupling the harness <NUM> to the coupling device <NUM> on each of the lifelines <NUM>. For example, in <FIG>, a worker (the load <NUM>) dons a harness <NUM> with two harness connectors <NUM> that are positioned on the worker's hips. In some applications, a third harness connector can be added on or near the worker's chest, and the number of lifelines <NUM> in the fall protection system <NUM> can be readily increased to accommodate additional harness connectors for a particular application. The harness <NUM> is any suitable harness and the harness connectors <NUM> are any suitable connectors that enable the fall protection system <NUM> to function as described herein. The harness <NUM> may be configured in any manner to accommodate any size and shape of the load <NUM>.

The fall protection system <NUM> is removably coupled to a system anchor point <NUM> affixed to or made a part of a rigid support structure <NUM> through the anchor <NUM> with a mechanical coupling. The rigid support structure <NUM> and the mechanical coupling to the system anchor point <NUM>, together with the fall protection system <NUM>, are configured to support a weight of the load <NUM> and any equipment carried by the load <NUM>, plus any dynamic acceleration force caused by a potential fall of the load <NUM> from the elevated position <NUM>. The system anchor point <NUM> is mechanically coupled to the rigid support structure <NUM> above the load <NUM> but may also be mechanically coupled to any location above the elevated platform <NUM> or mechanically coupled to the elevated platform <NUM>. The system anchor point <NUM> may also be positioned at any point along the length of the rigid support structure <NUM>. One or more pulleys <NUM> affixed to or made a part of the rigid support structure <NUM> may be used to create pulley anchor points <NUM> to provide separation of the lifelines <NUM> and permit the center of gravity of the load <NUM> to be between the lifelines <NUM> and between the pulley anchor points <NUM>. The pulleys <NUM> can be positioned in many numbers of configurations as needed for a particular application to provide for both two-dimensional and three-dimensional workspaces.

The fall protection system <NUM> is configured to extend each of the lifelines <NUM> independently in response to a pulling force (shown by arrows A and B) from the load <NUM> until a maximum length is reached. That is, if a pulling force is applied to one of the lifelines <NUM> (e.g., arrow A), then that lifeline will extend, and the other lifeline will retract. For example, if the load <NUM> is moved toward one of the pulley anchor points <NUM>, the lifeline associated with that one of the pulley anchor points <NUM> will retract automatically while the lifeline associated with the other of the pulley anchor points <NUM> will extend or be maintained in its position depending on where it is located. Thus, as the load <NUM> moves around or is moved in the elevated position <NUM>, the lifelines <NUM> selectively and independently extend and retract in response to that movement and the lifelines <NUM> are maintained in tension between the load <NUM> and the system anchor point <NUM> and the pulley anchor points <NUM> to reduce any interference with the load <NUM> and its movement.

If the load <NUM> falls from the elevated position <NUM>, a greater dynamic accelerating force will be applied to one or more of the lifelines <NUM> causing one or more of the lifelines <NUM> to rapidly extend from the fall protection system <NUM>. The fall protection system <NUM> is configured to mechanically sense when a speed of any one of the lifelines <NUM> increase to a threshold brake speed and, when it does, to simultaneously arrest movement of all the lifelines <NUM>, thus stopping the load <NUM> from falling further and preventing any horizontal movement or swing of the load <NUM>. The fall protection system <NUM> therefore eliminates the risk of a swing hazard by limiting the fall of a load <NUM> from an elevated position <NUM> to a deceleration distance set by the amount of time it takes for any one of the lifelines to reach the threshold brake speed and limiting the fall direction to a vertical direction (shown by arrow C). If extension of just one of the lifelines <NUM> is arrested, then the load <NUM> will swing in the horizontal direction (shown by arrow D) in addition to falling in the vertical direction, presenting the risk of the load <NUM> colliding with the rigid support structure <NUM> or personnel, equipment, or other structures below the elevated position <NUM>. This risk is eliminated by the fall protection system <NUM> disclosed herein by arresting movement of all lifelines <NUM> simultaneously in the event of a fall. It is not necessary for the lifelines <NUM> to be positioned equally around the load <NUM> so that the angles between the fall and each of the lifelines <NUM> are equal. In addition, the load <NUM> can "leap-frog" by, for example, transferring the one of the lifelines <NUM> on the harness connector <NUM> on the right side to the harness connector <NUM> on the left side when a center connection is reached. This is done safely as the fall protection system <NUM> maintains active fall protection during the transfer. The fall protection system <NUM> therefore provides improved functionality and cost-effectiveness as compared to using a trolley or multiple lifelines <NUM> having separate brakes.

<FIG> shows an exploded view of the fall protection system <NUM> including two or more self-retracting lanyards <NUM> and a single braking system <NUM> contained by the housing <NUM> (shown in <FIG>). The housing <NUM> includes the center body <NUM> and two end plates <NUM>, which close the open sides of the center body <NUM>. An end brake gear <NUM> of the single braking system <NUM> is welded or fastened to an interior surface of one of the two end plates <NUM> and provides a locking feature for the single braking system <NUM> supported by the one of the two end plates <NUM> of the housing <NUM>. The two end plates <NUM> are secured to the center body <NUM> with a plurality of bolts <NUM> that extend through one of the two end plates <NUM>, through the center body <NUM>, and through the other of the two end plates <NUM> and are secured with nuts <NUM>. The bolts <NUM> are positioned in recessed tracks <NUM> formed on an inner circumferential surface <NUM> of the center body <NUM>, which permit the bolts <NUM> to rotate within the recessed tracks <NUM>. A central axle <NUM> extends through the center body <NUM> and is welded, fastened, or otherwise secured to a central point <NUM> on each of the interior surfaces of the two end plates <NUM>.

Referring to <FIG>, each of the self-retracting lanyards <NUM> includes a spool <NUM>, a rotor spring <NUM>, a lifeline <NUM> as described above wound around the spool <NUM> in a circumferential recessed track <NUM> surrounding the spool <NUM>, and a coupling device <NUM> coupled to a distal end <NUM> of the lifeline <NUM>. The spool <NUM> has a recessed space <NUM> having a circular shape recessed into a side surface <NUM> of the spool <NUM> and a central hole <NUM> that extends through the width of the spool <NUM>. An outer edge <NUM> of the recessed space <NUM> forms a spool gear <NUM> that is operably engaged by or reacts with the single braking system <NUM>, as will be described herein. The central hole <NUM> of the spool <NUM> is aligned with a center of the recessed space <NUM> and in the housing <NUM> with the central point <NUM> on each of the two end plates <NUM> (see <FIG>). The spool <NUM> in each of the self-retracting lanyards <NUM> is configured to rotate independently around the central axle <NUM> of the fall protection system <NUM> and a torsion shaft <NUM> of the single braking system <NUM> as hereinafter described.

<FIG> illustrates a side view of one of the self-retracting lanyards <NUM> positioned in the center body <NUM> of the housing <NUM>. At least a second one of the self-retracting lanyards <NUM> is positioned behind or in front of the one shown in <FIG> (see <FIG>). The central axle <NUM> of the fall protection system <NUM> and the torsion shaft <NUM> of the single braking system <NUM> extend through the central hole <NUM> of the spool <NUM> in each of the self-retracting lanyards <NUM> and a circumferential edge <NUM> of the spool <NUM> in each of the self-retracting lanyards <NUM> is positioned against the bolts <NUM>, which act as rollers so the spool <NUM> is freely rotatable around the central axle <NUM> and the torsion shaft <NUM>. Alternatively, rollers can be provided around the central axle <NUM> or around the central hole <NUM> between the spool <NUM> and the central axle <NUM> to facilitate free rotation of the spool <NUM> around the central axle <NUM>.

The rotor spring <NUM> is a coiled spring having an interior end <NUM> positioned near a center of the coil and an exterior end <NUM> at an outer layer of the coil. The interior end <NUM> is attached to the spool <NUM> on the side of the spool <NUM> opposite the side surface <NUM> having the recessed space <NUM> with a pin <NUM> or any other suitable means for retaining interior end <NUM> in the desired position. The interior end <NUM> of the rotor spring <NUM> is positioned adjacent to a circumference of the central hole <NUM> in the spool <NUM>. The exterior end <NUM> of the rotor spring <NUM> is attached to the housing <NUM> with a rotor spring pin <NUM> that extends through a circumferential space <NUM> between the circumferential edge <NUM> of the spool <NUM> and an inner circumferential surface <NUM> of the center body <NUM> of the housing <NUM> and is welded, fastened, or otherwise secured to the two end plates <NUM>. The rotor spring pin <NUM> also extends through the exterior end <NUM> of the rotor spring <NUM>, which is formed into a loop, to provide an anchor point for the rotor spring <NUM> on the housing <NUM> and retain the exterior end <NUM> of the rotor spring <NUM> in position when the lifeline <NUM> is extended and retracted from the housing <NUM>.

The rotor spring <NUM> is biased to a neutral position so that it creates tension in the lifeline <NUM> when a pulling force is applied to the lifeline <NUM> (i.e., when the lifeline <NUM> is extended out of the center body <NUM> of the housing <NUM>, the rotor spring <NUM> is compressed) and the return action for the spool <NUM> when a pulling force is removed from the lifeline <NUM> (i.e., when the load <NUM> is moved closer to the spool <NUM>, the rotor spring <NUM> returns to the neutral position and causes the spool <NUM> to rotate the opposite direction to retract the lifeline <NUM> into the housing <NUM>). Referring to the arrangement shown in <FIG>, for example, an exterior pulling force applied to the lifeline <NUM> causes that lifeline to extend out of the center body <NUM> of the housing <NUM>, the spool <NUM> to rotate in a counter-clockwise direction, and the rotor spring <NUM> to compress because the interior end <NUM> of the rotor spring <NUM> is connected to the spool <NUM> by the pin <NUM>. When the exterior pulling force is removed from the lifeline <NUM>, the compressed rotor spring <NUM> causes the spool <NUM> to rotate in a clockwise direction and the lifeline <NUM> to retract back into the center body <NUM> of the housing <NUM> as it is wound around the spool <NUM>. Each of the self-retracting lanyards <NUM> in the fall protection system <NUM> perform these functions independently from one another. In other aspects of this disclosure, the rotor spring <NUM> may be configured with the interior end <NUM> and the exterior end <NUM> on the opposite side of the spool <NUM> so that extending the lifeline <NUM> out the housing <NUM> rotates the spool in a clockwise direction and retracting the lifeline <NUM> into the housing <NUM> rotates the spool in a counter-clockwise direction.

<FIG> shows a spool assembly <NUM> with two self-retracting lanyards <NUM> having two lifelines <NUM> positioned side-by-side. The self-retracting lanyards <NUM> are not attached to each other in the spool assembly <NUM>; they are placed adjacent to each other or can be spaced apart. Therefore, each of the self-retracting lanyards <NUM> performs the functions described above independently from other self-retracting lanyards <NUM> in the fall protection system <NUM>. Any number of self-retracting lanyards <NUM> may be included in the spool assembly <NUM> by positioning additional self-retracting lanyards <NUM> in a series next to each other as shown for example in <FIG> (showing four of the self-retracting lanyards <NUM>) or in other configurations that permit operation of the self-retracting lanyards <NUM> in accordance with this disclosure.

The single braking system <NUM> is shown in more detail in <FIG>. Referring first to <FIG>, the single braking system <NUM> includes at least two spool brake assemblies <NUM> connected by a torsion shaft <NUM> and at least one end brake assembly <NUM>. The number of spool brake assemblies <NUM> will be equal to the number of self-retracting lanyards <NUM> that are present in the fall protection system <NUM>. An additional torsion shaft <NUM> will be employed to join each additional one of the spool brake assemblies <NUM>. The torsion shaft <NUM> is connected to the spool brake assemblies <NUM> by welding or other means suitable to achieve the functions disclosed herein. The end brake assembly <NUM> is connected to one of the spool brake assemblies <NUM> by fasteners <NUM> or any other means suitable to achieve the functions disclosed herein. All of these components of the single braking system <NUM> freely rotate around the central axle <NUM> of the fall protection system <NUM> within the center body <NUM> of the housing <NUM>, i.e., the central axle <NUM> passes through the end brake assembly <NUM>, the spool brake assemblies <NUM>, and the torsion shaft <NUM> to permit them all to rotate around the central axle <NUM> at the same rotational speed. The central axle <NUM> is connected to the central point <NUM> of the end plates <NUM> of the housing <NUM> (see <FIG>).

Referring to <FIG>, each of the spool brake assemblies <NUM> includes a spool brake wheel <NUM>, at least one spool brake pawl <NUM>, and a spool brake spring <NUM> associated with of spool brake pawl <NUM>. Each spool brake pawl <NUM> is radially positioned around a circumference <NUM> of the spool brake wheel <NUM> to be movable between a compressed position <NUM> and an extended position <NUM>. The spool brake spring <NUM> biases the spool brake pawl <NUM> to have a neutral position in the extended position <NUM>.

If more than one spool brake pawl <NUM> is employed, they are radially positioned around the circumference <NUM> of the spool brake wheel <NUM> at unequal radial positions and/or unequal radial angles relative to each other, preferably no more than <NUM>° off from equal radial angles. For example, if there are three spool brake pawls <NUM> with equal radial angles, the equal radial angles between the spool brake pawls <NUM> are all <NUM>°; and if there are four spool brake pawls <NUM>, the equal radial angles are all <NUM>°. For the spool brake wheel <NUM> shown in <FIG> having three spool brake pawls <NUM> with unequal radial positions and/or unequal radial angles, the unequal radial angles between each of the spool brake pawls <NUM> are within a range of <NUM>° to <NUM>°, with the total of the unequal radial angles equal to <NUM>°; and for a spool brake wheel <NUM> having four spool brake pawls <NUM> with unequal radial positions and/or unequal radial angles, the unequal radial angles between each of the spool brake pawls <NUM> are within a range of <NUM>° to <NUM>°. <FIG> shows an example of a spool brake wheel <NUM> having three spool brake pawls <NUM> with unequal radial angles where a first radial angle "a" is <NUM>°, a second radial angle "b" is <NUM>°, and a third radial angle "c" is <NUM>°. However, many other configurations are possible, including increasing the number of spool brake pawls <NUM> and modifying the unequal radius angles between the spool brake pawls <NUM>, depending on the size and form of the fall protection system <NUM> and the designed maximum weight and deceleration distance after a fall.

Referring to <FIG>, the end brake assembly <NUM> includes an end brake rotary mount <NUM>, at least one end brake pawl <NUM>, and an end brake spring <NUM> associated with each end brake pawl <NUM>. The end brake pawl <NUM> is radially positioned around the end brake rotary mount <NUM> to be movable between a seated position <NUM> against a pawl stop <NUM> of the end brake rotary mount <NUM> and an activated position <NUM> where the end brake pawl <NUM> is moved away from the pawl stop <NUM>. The end brake spring <NUM> biases the end brake pawl <NUM> to have a neutral position in the seated position <NUM>.

Like the spool brake pawls <NUM> in <FIG>, if more than one end brake pawl <NUM> is employed, they are radially positioned around the end brake rotary mount <NUM> at unequal radial positions and/or unequal radial angles relative to each other, preferably no more than <NUM>° off from equal radial angles. Thus, when there are three end brake pawls <NUM>, the unequal radial angles between each of the end brake pawls <NUM> are in the range of <NUM>° to <NUM>°, with the total of the unequal radial angles equal to <NUM>°. If there are four end brake pawls <NUM>, the unequal radial angles between each of the end brake pawls <NUM> are in the range of <NUM>° to <NUM>°, with the total of the unequal radial angles equal to <NUM>°. <FIG> shows an end brake rotary mount <NUM> having three end brake pawls <NUM> with unequal radial positions and/or unequal radius angles including a first radial angle "a" equal to <NUM>°, a second radial angle "b" equal to <NUM>°, and a third radial angle "c" equal to <NUM>°. However, many other configurations are possible, including increasing the number of end brake pawls <NUM> and modifying the unequal radial angles between the end brake pawls <NUM>, depending on the size and form of the fall protection system <NUM> and the designed maximum weight and deceleration distance after a fall.

<FIG> and <FIG> illustrate how elements of the single braking system <NUM> react with elements of the self-retracting lanyards <NUM>. <FIG> illustrates a side view of the fall protection system <NUM> with the end plates <NUM> of the housing <NUM> removed to show the positioning of the spool <NUM> of one of the self-retracting lanyards <NUM>, one of the spool brake assemblies <NUM>, and the end brake assembly <NUM>. <FIG> illustrates a side view of the inner surface of one of the end plates <NUM> that has the end brake gear <NUM> attached thereto. Additional self-retracting lanyards <NUM> positioned behind the one shown in <FIG> will have another of the spool brake assemblies <NUM> positioned like shown in <FIG> but the end brake assembly <NUM> is attached only to the spool brake assembly closest to the end plate <NUM> with the end brake gear <NUM>. An additional end brake gear <NUM> may be used on the end plate <NUM> on the other side of the housing <NUM> if for example, in certain applications, it is desired to reduce reaction of time of the single braking system <NUM>, or if stress on the torsion shaft <NUM>, the end brake gear <NUM>, or the one or more end brake pawl <NUM> is too high when using one end brake gear <NUM>, or if the number or size of the self-retracting lanyards <NUM> is much greater, or if the fall protection system <NUM> is required to protect heavier weights.

Referring to <FIG>, the spool brake assemblies <NUM> are positioned in the recessed space <NUM> in the side surface <NUM> of the spool <NUM> of a respective one of the at least two self-retracting lanyards <NUM> to rotate around the central axle <NUM> and react directly with the spool gear <NUM> that surrounds the recessed space <NUM>. <FIG> shows a first arrangement of one of the spool brake assemblies <NUM> and the spool <NUM> of one of the at least two self-retracting lanyards <NUM>, with the end brake assembly <NUM>. Positioned in series behind the first arrangement shown in <FIG> is a second one of the at least two self-retracting lanyards <NUM> with a respective second one of the spool brake assemblies <NUM> positioned in the spool <NUM> of the second one of the at least two self-retracting lanyards <NUM> to rotate around the central axle <NUM>.

As previously described, all the spool brake assemblies <NUM> are joined together by the torsion shaft <NUM>, which extends through and rotates freely within the central hole <NUM> in the spool <NUM> and around the central axle <NUM>. Therefore, all the spool brake assemblies <NUM> rotate together at equal speeds around the central axle <NUM>. The spool brake assemblies <NUM> have no power to rotate on their own or to cause rotation of the spool <NUM> with which it interacts. Instead, the spool brake assemblies <NUM> are rotated only when the force on one of the lifelines <NUM> causes that lifeline to extend from the housing <NUM> and the at least one spool <NUM> associated with that lifeline to rotate.

In the example shown in <FIG>, the spool brake springs <NUM> in the spool brake assemblies <NUM> act on the spool brake pawls <NUM> so that the neutral position of the spool brake pawls <NUM> is in the extended position <NUM>. When a pulling force is applied to the lifeline <NUM> causing the lifeline <NUM> to extend out of the center body <NUM> of the housing <NUM>, the lifeline <NUM> rotates the spool <NUM> in a clockwise direction and the rotor spring <NUM> on the opposite side of the spool <NUM> compresses. As the spool <NUM> rotates in the clockwise direction, the teeth <NUM> in the spool gear <NUM> interact with the spool brake pawls <NUM> in the extended position <NUM>, which transfers the clockwise rotation of the spool <NUM> to the spool brake wheel <NUM>.

If the spool <NUM> in a second one of the self-retracting lanyards <NUM> is rotating faster than the spool <NUM> shown in <FIG>, the teeth <NUM> in the spool gear <NUM> of the spool <NUM> in the second one of the self-retracting lanyards <NUM> will interact with the spool brake pawls <NUM> in the extended position <NUM> of a second spool brake assembly associated with the spool <NUM> in the second one of the self-retracting lanyards <NUM>, which transfers the rotation of that spool <NUM> to the spool brake wheel <NUM> of the second spool brake assembly, which also transfers the clockwise rotation to all of the spool brake assemblies <NUM> and the end brake assembly <NUM> through the torsion shaft <NUM>. Due to the interaction of the spool brake assemblies <NUM> with the spool gear <NUM> on their respective spools, the spool brake springs <NUM> on the spool brake assembly associated with the spool <NUM> that is moving at a slower rotational speed will be compressed by the spool gear <NUM> as the spool brake assemblies <NUM> rotate in a clockwise direction. The spool brake assembly associated with the spool <NUM> that is moving at a slower rotational speed has no power to rotate that spool <NUM>.

Because the spool brake assemblies <NUM> are connected together through the torsion shaft <NUM> and the end brake assembly <NUM> is fastened to one of the spool brake assemblies <NUM>, the spool brake assemblies <NUM> and the end brake assembly <NUM> all rotate together at a rotational speed equal to the rotational speed of the spool <NUM> in the self-retracting lanyards <NUM> that is rotating the fastest. That is, the spool brake assemblies <NUM> and the end brake assembly <NUM> rotate at the same rotational speed as the spool <NUM> for a lifeline <NUM> in one of the self-retracting lanyards <NUM> that is being extended out of the housing <NUM> the fastest relative to the speed of lifelines in other self-retracting lanyards <NUM> in the fall protection system <NUM>. Further, the spool brake assemblies <NUM> are rotated by the fastest moving spool <NUM> and each spool <NUM> remains independent of any other spool <NUM> in the fall protection system <NUM>.

When the pulling force is removed from the lifeline <NUM>, for example when motion of the load <NUM> away from one of the self-retracting lanyards <NUM> stops, the rotor spring <NUM> expands and returns to its neutral position, causing spool <NUM> to rotate in a counter-clockwise direction and the lifeline <NUM> to be wound upon the spool <NUM>. As this occurs, spool gear <NUM> also rotates in the counter-clockwise direction and reacts with the spool brake pawls <NUM> to compress the spool brake springs <NUM> so that the spool brake pawls <NUM> move out of the motion of the spool gear <NUM> and do not interfere with the counter-clockwise rotation of the spool <NUM>. This allows the spool <NUM> to move in the counter-clockwise direction without rotating the spool brake assemblies <NUM>. Thus, each of the self-retracting lanyards <NUM> operates independently from each other in extending and retracting the lifeline <NUM> when the load <NUM> is maintained in the elevated position <NUM>.

<FIG> illustrates an example of an end brake gear <NUM> and its interaction with the end brake assembly <NUM> that is fastened to the first of the spool brake assemblies <NUM> in the series of spool brake assemblies <NUM>. The end brake gear <NUM> is directly connected, by welding or other means, to an interior surface of one of the end plates <NUM> of the housing <NUM> to prevent rotation of the end brake gear <NUM>. The end brake gear <NUM> provides a support for simultaneously arresting rotation of the end brake assembly <NUM>, the spool brake assemblies <NUM>, and the spool <NUM> in each of the self-retracting lanyards <NUM> when a fall occurs. An additional end brake assembly <NUM> may be used in the fall protection system <NUM> for example when several more of the self-retracting lanyards <NUM> are used or if additional arresting force is desired for a particular application. A second end brake gear would then be attached to the other of the two end plates <NUM> and the spool brake assembly closest to the other of the two end plates <NUM> can be configured with its spool gear <NUM> facing the other of the two end plates <NUM>.

As previously described, the end brake springs <NUM> cause the end brake pawls <NUM> to sit in their seated position <NUM> resting on the pawl stop <NUM> of the end brake assembly <NUM>. When the spool brake assemblies <NUM> rotate clockwise (i.e., when a lifeline <NUM> is being extended out of the housing <NUM>), the clockwise rotation is transferred to the end brake assembly <NUM> because it is directly connected to one of the spool brake assemblies <NUM> and a centrifugal force begins to act on the end brake pawls <NUM> to overcome the reaction of the end brake springs <NUM> and move the end brake pawls <NUM> away from the pawl stop <NUM>. The faster the end brake assembly <NUM> rotates, the further the end brake pawls <NUM> will extend away from the pawl stop <NUM>.

When the end brake assembly <NUM> reaches a rotational speed equal to a designed threshold brake speed, mechanically sensing when a speed of any one of the self-retracting lanyards <NUM> has increased to the threshold brake speed (and indicating a fall), the end brake pawls <NUM> will extend further to the activated position <NUM> where the end brake pawls <NUM> interact with teeth <NUM> of the end brake gear <NUM>. The end brake assembly <NUM> rotates with the spool brake assemblies <NUM> at a rotational speed of the fastest spool <NUM> until it reaches the threshold brake speed when the end brake pawls <NUM> interact with the end brake gear <NUM> to simultaneously arrest rotation of the end brake assembly <NUM>, the spool brake assemblies <NUM>, and the spool <NUM> in each of the self-retracting lanyards <NUM>, thus arresting motion of all lifelines <NUM>. For illustration purposes, <FIG> shows the end brake pawls <NUM> in both the seated position <NUM> and the activated position <NUM>. In use, all the end brake pawls <NUM> will move from the seated position <NUM> to the activated position <NUM> at the same time due to the centrifugal force when end brake assembly <NUM> rotates. The end brake pawls <NUM> are configured at unequal radial positions and/or unequal radial angles relative to each other as previously described to reduce the distance the end brake assembly <NUM> rotates before one of the end brake pawls <NUM> engages with the end brake gear <NUM>.

There are many considerations in the design of the fall protection system <NUM> that would affect the threshold brake speed at which the single braking system <NUM> engages to arrest movement of the self-retracting lanyards <NUM>. For example, the centrifugal force that counteracts the end brake spring <NUM> associated with an end brake pawl <NUM> is affected by the mass, size, and speed of the end brake pawl <NUM>, the position of the end brake pawl <NUM> from a center axis of the end brake rotary mount <NUM>, and the distance the end brake pawl <NUM> has to travel before it contacts the end brake gear <NUM>. The end brake spring <NUM> should be selected to counteract the centrifugal force, for example, by selecting an end brake spring <NUM> to have a constant (k) value and physical properties (size, material, wire diameter, total diameter) to achieve the desired result. In addition, when a diameter of the spool <NUM> in the self-retracting lanyards <NUM> is larger, the slower the fall protection system <NUM> will spin the end brake assembly <NUM>. These design considerations are application dependent, for example when minimizing or eliminating fall distance and impact force for different load types and weights, and may be constrained by a federal standard, such as the Occupational Safety and Health Administration ("OSHA"). It will be appreciated that these design considerations might be complex and time-consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art.

Referring to both <FIG> and <FIG>, together with <FIG> and <FIG>, when a load <NUM> falls from an elevated position <NUM>, for example off an elevated platform <NUM>, the single braking system <NUM> will be engaged to simultaneously arrest movement of all lifelines <NUM> out of the housing <NUM> of the fall protection system <NUM> when the single braking system <NUM> mechanically senses that any one of the lifelines <NUM> reaches a designed threshold brake speed (i.e., that indicates the load <NUM> is falling). First, as configured in these drawings, clockwise rotation of the end brake assembly <NUM> is arrested when the speed of the clockwise rotation reaches the threshold brake speed by the end brake pawls <NUM> interacting with the end brake gear <NUM>, which is secured to one of the end plates <NUM> of the housing <NUM>. Thus, the housing <NUM> provides a support for the arresting motion. Because the end brake assembly <NUM> is directly connected to a first of the spool brake assemblies <NUM>, clockwise rotation of the first spool brake assembly is arrested. The first spool brake assembly is directly connected to all of the spool brake assemblies <NUM> in the series through the torsion shaft <NUM>. Therefore, clockwise rotation of all the spool brake assemblies <NUM> is arrested at the same time. With the spool brake assemblies <NUM> stopped, the spool brake pawls <NUM> on the spool brake assemblies <NUM> in the extended position <NUM> interact with the spool gear <NUM> on the respective spools to simultaneously arrest clockwise rotation of the spool <NUM> in each of the self-retracting lanyards <NUM> after a short distance until one of the spool brake pawls <NUM> interacts with the spool gear <NUM>. With rotation of all of the spools arrested, the lifelines <NUM> cannot be extended any further from the housing <NUM>. That is, movement of all the self-retracting lanyards <NUM> in the fall protection system <NUM> is arrested. Therefore, the fall of the load <NUM> is arrested at each point on the load <NUM> that is connected to a lifeline <NUM>.

Referring again to <FIG>, where the load <NUM> is a worker walking around an elevated platform <NUM>, the fall protection system <NUM> is connected to the rigid support structure <NUM> above the worker, and the worker is connected to two lifelines <NUM> of self-retracting lanyards <NUM> in the fall protection system <NUM>, one on the left side and one on the right side of the worker. When the worker walks to the right, the lifeline on the left will be extended and the lifeline on the right will be retracted. More particularly, the lifeline on the left rotates the spool <NUM> associated with that lifeline in a clockwise direction as it extends from the housing <NUM>. The spool <NUM> associated with the lifeline on the left reacts with the spool brake pawls <NUM> of the spool brake assembly associated with the spool <NUM> and rotates the spool brake assembly in a clockwise direction at the same rotational speed of the spool <NUM>. The spool brake assembly reacts with all of the spool brake assemblies <NUM> in the series and rotates them in a clockwise direction at the same speed.

At the same time, the spool <NUM> associated with the lifeline on the right rotates in a counter-clockwise direction due to the rotor spring <NUM> returning to its neutral position and causes the lifeline on the right to retract into the housing <NUM>. The spool brake assembly associated with the spool <NUM> and lifeline on the right continues to rotate in a clockwise direction at the same speed as the spool brake assembly associated with the lifeline on the left due to the direct connection of all the spool brake assemblies <NUM> through the torsion shaft <NUM>. The spool brake springs <NUM> in the spool brake assembly <NUM> associated with the lifeline <NUM> on the right compress as the spool brake pawls <NUM> react with the spool gear <NUM>, allowing independent motion of the spool <NUM> associated with the lifeline on the right and the spool <NUM> associated with the lifeline on the left. In this scenario, the end brake assembly <NUM> rotates in a clockwise direction at the same rotational speed as the spool brake assemblies <NUM>. The end brake pawls <NUM> extend from the pawl stop <NUM> due to centrifugal force, but not enough to interact with the end brake gear <NUM> because the rotational speed of the end brake assembly <NUM> has not reached the threshold brake speed.

In a scenario like the one just described, but where the load <NUM> falls from the elevated position <NUM> nearest to the pulley anchor point <NUM> on the left side of the rigid support structure <NUM>, the end brake assembly <NUM> will engage the end brake gear <NUM> and arrest movement of both lifelines <NUM> at the same time. In this scenario, the lifeline on the left rapidly rotates the spool <NUM> associated with that lifeline in a clockwise direction as that lifeline rapidly extends from the housing <NUM>. The spool <NUM> reacts with the spool brake pawls <NUM> of the spool brake assembly <NUM> associated with the spool <NUM> and rotates the spool brake assembly <NUM> in a clockwise direction at the same rotational speed of the spool <NUM>. The spool brake assembly <NUM> reacts with all of the spool brake assemblies <NUM> in the series and rotates them in a clockwise direction at the same speed.

In this scenario, the lifeline on the right also rotates the spool <NUM> associated with that lifeline in a clockwise direction because that lifeline will also be extended from the housing <NUM>, but at a slower speed. The spool brake assembly <NUM> associated with the spool <NUM> and the lifeline on the right rotates in a clockwise direction at the same faster speed as the spool brake assembly associated with the lifeline on the left due to the direct connection of all the spool brake assemblies <NUM> through the torsion shaft <NUM>. The spool brake springs <NUM> in the spool brake assembly <NUM> associated with the lifeline on the right compress as the spool brake pawls <NUM> react with the spool gear <NUM>, allowing independent motion of the spool <NUM> associated with the lifeline on the right and the spool <NUM> associated with the lifeline on the left.

The end brake assembly <NUM> rotates in a clockwise direction at the same rotational speed as the spool brake assemblies <NUM> (i.e., the rotational speed of the fastest moving spool <NUM>, in this scenario, the spool <NUM> associated with the lifeline on the left). The end brake pawls <NUM> extend from the pawl stop <NUM> in the end brake assembly <NUM> due to centrifugal force. When the end brake assembly <NUM> reaches the threshold brake speed, mechanically sensing a fall, at least one of the end brake pawls <NUM> will interact with the end brake gear <NUM> and therefore stop further rotation of the end brake assembly <NUM>. Due to the direct connection with the spool brake assemblies <NUM>, the end brake assembly <NUM> stops the spool brake assemblies <NUM> from rotating. Because the load <NUM> is falling, the lifelines <NUM> on the right side and the left side will each continue to apply a pulling or clockwise rotational force to their respective spools, but the spool gear <NUM> in each spool <NUM> reacts with one or more of the spool brake pawls <NUM> in their respective spool brake assemblies <NUM>, which prevents rotation of the spool <NUM> in each of the self-retracting lanyards <NUM> and further extension of the lifelines <NUM>. The vertical distance from when the fall begins to when the fall is arrested is limited by the radial angles between the end brake pawls <NUM> and radial angles between the spool brake pawls <NUM>. The load <NUM> cannot move in a horizontal direction because all the lifelines <NUM> stop moving at the same time. Therefore, swing hazards are eliminated.

<FIG> shows a method <NUM> for protecting a load <NUM> when falling from an elevated position <NUM>. In method step <NUM>, at least two self-retracting lanyards <NUM> are removably coupled to the load <NUM> (as shown in <FIG>). In method step <NUM>, the two self-retracting lanyards <NUM> are operated independently when the load <NUM> is maintained in the elevated position <NUM>. In method step <NUM>, the method mechanically senses when a speed of any one of the at least two self-retracting lanyards <NUM> has increased to a threshold brake speed, and in method step <NUM>, when it is sensed that the speed of any one of the at least two self-retracting lanyards <NUM> has increased to the threshold brake speed, engaging a single braking system <NUM> associated with the at least two self-retracting lanyards <NUM> to arrest movement of the at least two self-retracting lanyards <NUM>.

The method <NUM> also includes configuring the at least two self-retracting lanyards with respective lifelines wound on respective spools that are configured to rotate around a central axle and torsion shaft independently of each other. That is, each of the at least two self-retracting lanyards has a spool with a lifeline wound upon it. In the method step <NUM>, engaging the single braking system comprises engaging an end brake gear to simultaneously arrest movement of the respective spools when mechanically sensing that a rotational speed of a first spool associated with one of the two self-retracting lanyards or a spool associated with a second of the two-self-retracting lanyards has increased to the threshold brake speed, and more particularly, engaging, by the at least one pawl, the end brake gear to arrest movement of the single braking system and the respective spools, and therefore all of the lifelines in the self-retracting lanyards. In the method step <NUM>, mechanically sensing comprises deploying at least one pawl that is movable by centrifugal force acting against a spring force to engage a spool gear when a rotational speed of a first spool of the respective spools or a second spool of the respective spools has increased to the threshold brake speed. The method <NUM> also includes configuring the single braking system to rotate at a rotational speed that is equal to a fastest rotational speed of a fastest one of the respective spools and configuring a spool brake assembly having at least one pawl acting against a spring force where a neutral position of the spring force is in an extended position to react with a recessed spool gear in at least one of the respective spools. The method <NUM> is applicable where the load is a worker, a cable-suspended platform, or a cable-suspended scaffolding.

In another method of making a fall protection system, the method includes the steps of positioning at least two self-retracting lanyards in a housing of the fall protection system and associating the at least two self-retracting lanyards with a single braking system that arrests movement of the at least two self-retracting lanyards if a speed of any one of the at least two self-retracting lanyards increases to a threshold brake speed.

Many modifications of the systems and methods disclosed herein may occur to those skilled in the art upon reading the specification including, for example, modifying the form or size of the fall protection system, or modifying the specific structure of the braking system and the gears therein. The present application includes such modifications and is limited only by the scope of the claims. The method claims set forth hereinafter should not be construed to require that the steps recited therein be performed in alphabetical order (any alphabetical ordering in the claims is used solely for the purpose of referencing previously recited steps) or in the order in which they are recited unless the claim language explicitly specifies or states conditions indicating a particular order in which some or all of those steps are performed. Nor should the method claims be construed to exclude any portions of two or more steps being performed concurrently or alternatingly unless the claim language explicitly states a condition that precludes such an interpretation.

Claim 1:
A fall protection system (<NUM>) for a load (<NUM>) in an elevated position, the fall protection system comprising at least two self-retracting lanyards (<NUM>) configured to be removably coupled to the load (<NUM>), the at least two self-retracting lanyards (<NUM>) associated with a single braking system (<NUM>) that arrests movement of the at least two self-retracting lanyards (<NUM>) when the single braking system (<NUM>) mechanically senses a speed of any one of the at least two self-retracting lanyards (<NUM>) has increased to a threshold brake speed; wherein
the at least two self-retracting lanyards (<NUM>) comprise respective lifelines (<NUM>) wound on respective spools (<NUM>), and the respective spools (<NUM>) are independently rotatable around a central axle (<NUM>) of the fall protection system (<NUM>);
characterised in that:
the single braking system (<NUM>) comprises an end brake assembly (<NUM>) and at least two spool brake assemblies (<NUM>) respectively associated with the respective spools (<NUM>);
the end brake assembly (<NUM>) is connected to one of the spool brake assemblies (<NUM>) and comprises at least one end brake pawl (<NUM>);
the at least two spool brake assemblies (<NUM>) and the end brake assembly (<NUM>) are rotatable around the central axle (<NUM>) of the fall protection system at a rotational speed equal to a fastest rotational speed of one of the respective spools (<NUM>) that is rotating faster than any other of the respective spools (<NUM>); and
at least one end brake pawl (<NUM>) is movable by centrifugal force acting against a spring force and positioned to engage an end brake gear (<NUM>) to arrest movement of the at least two spool brake assemblies (<NUM>) and the respective spools (<NUM>) when at least one of the respective spools (<NUM>) has reached the threshold brake speed.