Crane and method of operating a crane with energy recovery from crane operations as a secondary sour

专利摘要:
Crane (1) having a power consumer system (22) of a primary energy source (12) and a independently controllable secondary energy source (25) comprising at least one crane component with at least one connected to the power consumer system energy storage unit (23) at least one drive motor (40) and a Control unit, wherein a control unit (120) comprises a non-transitory computer-readable medium with stored software and further comprising at least one connected to the crane component energy converter and wherein the control unit controls a ratio of energy use share to energy storage component.
公开号:AT15760U1
申请号:TGM50002/2017U
申请日:2011-12-07
公开日:2018-05-15
发明作者:
申请人:Terex Global Gmbh；
IPC主号:

专利说明:

Description: [0001] The invention relates to a crane, in particular a large crane, and to a method for operating a crane, and in particular electrically operated cranes.
Large cranes are known by public prior use for some time. Such machines are used, for example, for lifting loads and have to fulfill complex operations on a variety of drives and units, which may have a cumulative power of up to 1000 kW. The energy consumption and the emitted pollutants of such a crane are correspondingly high.
EP 2 065 331 A2 discloses a method and an apparatus for operating a crane as well as improvements in or relating to the generation of electricity. JP 2001-163574 A discloses a crane with a gantry structure, wherein a movable frame with a lifting device for lifting and lowering a container spreader for gripping a container is provided. DE 40 08 370 A1 discloses a system for supplying energy to a crane.
DE 10 2004 010 988 A1 shows a hybrid drive system for a gantry lift truck with a static electrical energy storage and a short-term energy storage. Both energy stores are connected via a respective control unit with a central DC voltage intermediate circuit.
Further machines with different power supplies and / or energy management systems are known from EP 1 813 462 A1, DE 200 10 030 U1, DE 100 48 831 B4 and DE 10 2004 028 353 A1.
From US 7,554,278 B2 a load lifting device is known, which uses energy recovered to power the device, which is released, for example, when lowering a load. US 5,936,375 discloses a method for storing and reusing energy for a load lifting system. The storage of energy is based on batteries, which may be extended by, for example, a flywheel due to their limited storage capacity. This form of energy storage is complex and involves higher energy losses due to the increased number of components.
From DE 10 2007 046 696 A1 discloses a hydraulically operated crane is known, which can be operated hybrid. However, it is difficult to control hydraulically operated cranes and to determine in advance how much energy is needed to operate the crane; moreover, the methods taught in connection with the use of hydraulically operated cranes can not be applied to electric cranes.
It is an object of the invention to provide a crane such that the fuel consumption and the emission of exhaust gases and noise are reduced, especially taking into account a mobile large crane underlying operation in intermittent operation.
To solve the posed object, the invention provides a crane and a method as specified in the claims.
Thus, there is provided a crane having a power consumer system for providing power to at least one secondary energy source independently controllable from the primary energy source for injecting secondary energy into the power consumer system, wherein the secondary energy source is connected to the power consumer system and configured to recover energy returned from crane operation at least partially fed into the power consumer system as secondary energy, wherein the secondary energy source at least one crane component, at least one energy storage unit, which is arranged decentralized to the crane, the crane associated with the at least one crane component and connected to the power consumer system for storing primary energy and / or secondary energy is, as well as at least one drive motor includes, which is used for operating the at least one crane component in dependence on in the power consumer system eister energy is connected to the power consumer system. "Decentralized" with respect to the arrangement of the energy storage unit means that the energy storage unit is not centrally, e.g. via the power consumer system, all crane components is available. This means that the crane components that are not assigned to the energy storage unit have no or no direct access to the energy storage unit. This makes it possible the decentralized energy storage unit, which is assigned in particular only a few crane components and in particular only one crane component, smaller, so in space, resource and cost-saving manner to perform in the crane. In particular, the decentralized energy storage unit is assigned to the at least one crane component.
The crane comprises a control unit which is in signal communication with the power consumer system, the primary energy source and the at least one secondary energy source for controlling the power supply of the at least one crane component.
The control unit comprises a non-transitory computer-readable medium having stored software for performing the steps of providing a total energy amount comprising a primary energy generated by the primary energy source and / or a secondary energy generated by the at least one secondary energy source, calculating one of the at least one crane component requested Energieutzanteils, and storing an energy storage component in the at least one energy storage unit, wherein the total energy amount includes the Energieutzanteil and the energy storage component, and wherein the secondary energy is recycled from performed by the at least one crane component workflows.
The crane further comprises at least one energy converter connected to the at least one crane component for converting energy from the at least one crane component into power, wherein the software comprises the step of providing the energy share to the at least one crane component by means of the power from the at least one energy converter performs.
The control unit regulates a ratio of energy use component to energy storage component.
According to one embodiment, there is provided a data bus enabling bi-directional data transfer, the data bus being connected to the control unit and also to the power consumer system for providing the control unit with electrical input and output variables.
The primary energy source may be configured to be activated when a start condition is met, and deactivated when a stop condition is met.
The stop condition is met if at least one of the following conditions is met: a) there is no request for a hydraulic power; b) there is a battery voltage within preset limits; c) the cooling water temperature of the primary energy source is within the limits; d) the temperature of the pressurized oil is within the limits; e) if only auxiliary components connected to receive power only from the secondary power source are turned on, and f) other stop conditions that can be individually specified by a user.
The primary energy source may include an internal combustion engine, a transmission connected to a clutch to the internal combustion engine, and a generator.
The primary source may comprise a diesel engine.
In one embodiment, the crane further comprises auxiliary components connected to the power consumer system for receiving power only from the secondary energy source.
The crane may further comprise at least one fuel cell connected to the primary energy source to supplement the energy output from the primary energy source.
According to one embodiment, the at least one crane component comprises a slewing gear or a hydraulic or electric linear drive, an energy converter and an electric motor.
Preferably, the energy converter comprises a consumer gear or a hydraulic pump. In one embodiment, the crane further comprises at least one power consumer connected to the power consumer system, the system providing power to the at least one power consumer from the primary power source.
Preferably, the crane further comprises at least one power consumer connected to the power consumer system, the system providing the at least one power consumer with power from the at least one secondary power source.
The at least one secondary energy source may include an internal combustion engine.
The crane may further include a primary energy source radiator for cooling the primary energy source and a secondary energy source radiator in cooling communication with the primary energy source radiator for cooling the primary energy source and / or the secondary energy source.
According to one embodiment, the control unit is designed to supply the crane with energy from the secondary energy source in emergency operation.
The primary energy source may include a diesel engine, at least two primary source generators that convert the mechanical energy from the diesel engine into electrical energy that is fed into the power consuming system via rectifiers, and a clutch and transmission connected together and between the diesel engine and the engine at least two primary source generators are connected to transfer the mechanical energy from the diesel engine to the at least two primary source generators.
The crane may further include a cooling water supply connected to the rectifiers and the primary power source generators.
According to one embodiment, the crane comprises an undercarriage, a superstructure rotatably mounted on the undercarriage, a hydraulic pump, a plurality of hydraulic cylinders connected to support the undercarriage, a transducer, and an electric motor provided with the hydraulic pump, the converter and the power consumer system is connected to convert energy from the power consumer system into hydraulic energy that is supplied to the hydraulic pump to control the positioning of the undercarriage.
Preferably, the crane further comprises a super lift mast on the uppercarriage, a pressure transmitter connected to the superlift mast for detecting and transmitting an angular position of the superlift mast to a control device.
The at least one crane component may comprise at least one slewing gear, an associated rotary drive, which is connected to the at least one slewing gear, at least one associated electric motor, which is connected to the at least one rotary drive to convert rotational movements of the at least one rotary drive into electrical energy and a converter connected to the at least one electric motor to supply the power consuming system with electrical energy.
In one embodiment, the crane further includes an external power supply configured to supply mains power to the power consumer system.
According to one embodiment, the at least one crane component has at least one slewing gear and the crane has a central switching unit, which is connected to all of the at least one slewing gear and the power consumer system for converting the rotational movement of the at least one slewing gear into electrical energy, which serves as secondary energy supplied to the power consumer system.
According to one embodiment, the power consumer system has two power lines.
The crane may comprise a winch, the winch comprising a cable drum having a central cavity, an electric motor having a drive shaft extending along a central longitudinal axis of the central cavity, a first winch holder connecting the winch to the electric motor connects, a transmission housing near a distal end of the drive shaft, a fixed planetary gear, which is connected to the transmission housing and the drive shaft, a second winch holder, which is connected to the fixed planetary gear on a side facing the transmission housing, and a brake which with a End of the drive shaft is connected on an opposite side of the winch holder of the planetary gear. The electric motor and the transmission can drive the winch so that it winds a rope on the cable drum and thereby lifts a load, and the electric motor acts as a generator to generate electrical energy when the cable is driven by the transmission and the drive shaft is to lower the load.
A crane according to another embodiment comprises a secondary energy storage unit centrally located on the crane for storing excess energy from the primary energy source and / or the secondary energy source.
According to one embodiment, the secondary energy storage unit comprises a battery pack which is arranged as a stackable counterweight on the crane.
According to one embodiment, the secondary energy storage unit comprises a battery pack which is arranged as a super-lift counterweight on a crane-separated counterweight car.
Preferably, the secondary energy source has a maximum available power Ps, max which is less than a maximum available power PP, max of the primary energy source, where Ps, max - OjöPp ^ max- [0041] According to one embodiment, the software executes the A step of causing the provision of power to maintain the energy share from the energy storage unit in preference to energy supplied from the primary energy source.
Preferably, the software comprises the step of regulating the power supply to particular crane components in preference to other crane elements.
According to one embodiment, the software performs the steps of activating at least one crane component in a crane operating mode, deactivating the at least one crane component in an idling mode of the crane, and controlling the crane operation so that at intermittent operation, the ratio of operating duration during operation for operation in idle mode is not more than 0.3.
[0044] Preferably, the software executes the step of providing the energy share for the at least one crane component by injecting energy into the power consumer system.
According to one embodiment, the control unit calculates an excess amount of energy, so that a sum of the energy use fraction and a maximum energy storage fraction is equal to a sum of the excess energy fraction and the total energy amount.
According to one embodiment, the control unit regulates the reduction of the excess energy component by converting the energy generated by additional braking resistors into heat energy, wherein a return of the heat energy to the crane is used to heat a crane cab.
Preferably, the software performs the following step of causing the provision of power to maintain the energy share from the energy storage unit in preference to energy supplied from the primary energy source.
According to one embodiment, the software comprises the step of regulating the power supply to certain crane components in preference to other crane elements.
It is a further object of the invention to provide a method of operating a crane such that it can be operated with reduced fuel consumption and reduced emissions of exhaust gases and noise.
This object is achieved according to the invention by a method which comprises: activating the at least one crane component during operation of the crane; Deactivating the at least one crane component during idling operation of the crane; Control of crane operation, so that in the intermittent operation, a ratio of operating time in the working mode to an operating time in idle mode is at most 0.3; Providing a total energy amount comprising at least one of the primary energy provided by the primary energy source and secondary energy provided by the at least one secondary energy source; Determining an energy usage fraction required for at least one crane component, the at least one crane component being configured as a secondary energy source for energy recovery; and storing an energy storage portion in the at least one energy storage unit, the total energy amount comprising the energy usage portion and the energy storage portion, and wherein the secondary energy is energy derived from operations performed by the at least one crane component.
The Energieutzanteil is the at least one crane component provided by feeding into the power consumer system. According to a further embodiment, the energy-use component is provided by at least one energy converter, which is connected to the at least one crane component, for converting energy from the at least one crane component into power.
A ratio of the Energieutzanteils to the energy storage component is controlled by a control unit.
An excess amount of energy is calculated by the control unit so that a sum of the Energieutzanteil and a maximum energy storage component is equal to a sum of the excess energy share and the total energy.
A reduction of the energy surplus component is regulated by converting the energy obtained by additional braking resistors into thermal energy, wherein a return of the heat energy to the crane is used to heat a crane cab.
A method of operating a crane comprises providing power to at least one crane component by means of a power consumer system, injecting primary energy into the power consumer system using a primary energy source, operating the at least one crane component via at least one motor connected to the power consumer system, feeding of secondary energy in the power consumer system by returning the secondary energy from the operation of at least one crane component as a secondary energy source, which is independently controlled from the primary energy source, and storing the primary energy and / or the secondary energy by means of at least one decentralized arranged on the crane and connected to the power consumer system energy storage unit.
A method for operating a crane is provided. The crane comprises at least one crane component, a primary energy source, at least one secondary energy source, and a power consumer system connected to the at least one crane component, the primary energy source, and the at least one secondary energy source to supply the at least one crane component with energy from the primary energy source and / or the at least one to provide a secondary energy source. The method comprises the steps of providing a total energy amount comprising a primary energy generated by the primary energy source and / or a secondary energy generated by the at least one secondary energy source, calculating an energy utilization component requested by the at least one crane component, and storing an energy storage component in the at least one energy storage unit, wherein the total energy amount comprises the energy usage fraction and the energy storage fraction, and wherein the secondary energy from operations is recovered energy performed by the at least one crane component.
The method preferably further comprises the steps of activating the at least one crane component in the crane's working mode, deactivating the at least one crane component when the crane is idling, controlling the crane operation, such that in the intermittent operation, a ratio of operating time in the working mode to operating time in idle mode is at most 0.3.
The method preferably comprises the step of providing the energy share to the at least one crane component by causing a feed of energy into the power consumer system.
The method further comprises in particular the steps of converting energy from the operation of the at least one crane component into power by means of at least one energy converter connected to the at least one crane component and providing the energy share for the at least one crane component via the power of the at least one energy converters.
The method further advantageously comprises the step of regulating the energy supply of the at least one crane component by regulating the ratio of the energy use component to the energy storage component.
The method also preferably includes the step of calculating an excess amount of energy so that a sum of the energy share and a maximum amount of energy storage equals a sum of the excess amount of energy and the total amount of energy. According to one embodiment, the method further comprises the step of reducing the excess energy fraction by converting the energy derived from additional braking resistors into thermal energy, utilizing feedback of the thermal energy to the crane for heating a crane cabin.
According to one embodiment, the control unit is capable of regulating the crane operation in optionally four modes of operation, the four modes of operation being a standby mode, a half-hybrid mode, a full-hybrid mode and a full-electric mode.
According to one embodiment, in the standby mode, during a stop function, at least one auxiliary function may be activated by the secondary power source when the primary power source is deactivated.
Furthermore, in the half-hybrid mode, both the primary energy source and the electric drives for the at least one crane component can be used to generate energy for operating the crane.
According to one embodiment, in full hybrid mode, energy reserves from the energy storage units or electrical energy from the secondary energy sources can be used prior to energy from the primary energy source to operate the crane.
According to one embodiment, only electric power sources for operating the crane can be used in full electric mode.
In one embodiment, the crane further comprises an input device that allows a crane operator to change between the four modes of operation.
Preferably, the control unit comprises a module which automatically determines which operating mode to use and allows the control unit to switch to the determined mode.
A winch may comprise a cable drum having a central cavity, an electric motor having a drive shaft extending along a central longitudinal axis of the central cavity, a first winch holder connecting the winch to the electric motor, a gear housing near the remote end the drive shaft, a fixed planetary gear, which is connected to the transmission housing and the drive shaft, a second winch holder, which is connected to the fixed planetary gear on a side opposite the transmission housing side, and having a brake with one end of the drive shaft on an opposite Side of the winch holder is connected by the planetary gear. The electric motor and the transmission can drive the winch so that it winds a rope on the cable drum and thereby lifts a load, and the electric motor acts as a generator to generate electrical energy when the cable is driven by the transmission and the drive shaft is to lower the load.
Embodiments of the invention are explained below with reference to the drawing. 1 shows a schematic side view of a tired crane according to the invention in accordance with a first exemplary embodiment with a secondary energy source arranged in an uppercarriage of the crane and a telescopic boom. FIG. 2 shows a side view of a crawler crane according to a second embodiment Fig. 3 is an enlarged sectional view of Fig. 2, Fig. 4 is a schematic diagram of a power supply wiring diagram of the crane of Fig. 2, Fig. 5 a schematic representation of another embodiment of the
Cranes according to Fig. 4, Fig. 6 is a schematic representation of a control circuit with the associated
7 shows a flow chart for operating an energy management system of a crane according to the invention, FIG. 8 shows a flow chart for selecting an operating mode of a crane according to the invention, FIG. 9 shows a longitudinal section 2 and FIG. 10 shows a side view of a crawler crane according to a third embodiment, for example with superlift mast and counterweight car.
The present crane has at least one secondary energy source independent of the primary energy source, for feeding secondary energy into the power consumer system, except for a primary energy source for feeding primary energy into a power consumer system. In this case, the at least one secondary energy source is designed such that energy returned from the operation of the at least one secondary source is at least partially fed into the power consumer system as secondary energy. For example, the secondary energy source may be the crane components themselves, with energy being gained from the operation of these components. This makes it possible to supply the energy required to supply at least one drive motor connected to the power consumer system for operating at least one crane component with energy from the power consuming system which has not been generated exclusively and extra by the primary energy source. This makes it possible to reduce the running time and thus the energy consumption and the pollutant emissions of the primary energy source, which may be designed, for example, as a diesel engine. This may also allow the primary energy source to be smaller, i. H. with a lower performance than a comparable crane without a secondary energy source.
In the case of the crane, the at least one crane component can be used as a secondary energy source and thus enables functional integration of the crane. This means that, on the one hand, the secondary energy source can be used to provide energy to the crane and, on the other hand, the secondary energy source can be one of the at least one crane components providing various functions for the crane. Accordingly, the design allows at least one crane component as a secondary energy source, the connection of the function of the crane component itself, z. As for driving the crane, with the function of providing secondary energy for the crane. A crane component that can be used as a secondary energy source combines two different functions, usually realized by two different components, in one component. Thus, a reduction in size and an increase in the efficiency of the energy supply of the crane can be achieved. For example, it is possible for a winch to be used as a crane component for winding and unwinding a rope, whereby for rolling up the rope, i. H. for lifting a load, the winch must be driven by a corresponding drive component of the crane component. When lowering the load, d. H. when unwinding the cable, the winch serves as a secondary energy source, wherein the energy returned from the lowering of the load can be at least partially fed into the power consumer system and available for further use. Due to the large geometry of a crane, d. H. because of long boom and high lift heights, this offers a great potential for traceable secondary energy. In particular, the energy saving potential of a crane is greater than that of an excavator or other construction machinery. Thus arise for a large crane according to the invention as a semi-hybrid or fully hybrid system a variety of options for energy supply, energy recovery and energy storage.
By energy recycling system inherent forces and energies are used targeted in the crane. As a consequence, it is possible to equip a large crane for utilizing a potential energy recovery potential with correspondingly large motors and / or generators. Since the total crane weight is not of primary importance, especially in the case of a crawler crane, the maximum recovered power of the secondary energy sources can exceed a current maximum total energy amount of the crane, so that the secondary energy can also be fed into a service network. The crane serves as a power plant in this case.
It is also possible to design the crane such that the secondary energy source is not the crane components utilizing energy recovered from the crane operation, but instead a separate source. The secondary power source may be, for example, an internal combustion engine or a battery power source that has lower power compared to the primary power source. This smaller internal combustion engine can be operated and used independently of the primary energy source, for example, in order to supply, for example, smaller, in particular electrical consumers such as an air conditioning system or other electrical consumers with energy. Furthermore, at least one energy storage unit connected to the power consumer system is provided for storing the primary energy and / or the secondary energy. The energy storage unit is arranged decentralized on the crane and in particular is associated with the at least one crane component. This makes it possible to ensure the required energy supply for main functions of the crane, such as lifting, driving, turning and / or pivoting movements of the crane close to the location of the respective crane component. This means that the local distance from a place where needed energy is provided to a corresponding crane component is reduced, and in particular that distance is minimized. Typically, transmission losses are proportional to a length of a power transmission link. As a result, transmission losses can be reduced and in particular avoided, whereby the overall efficiency of the energy supply of the crane is improved.
The energy supply of the crane can be controlled in a particularly effective and energy-efficient manner with a control unit which is in signal connection with the power consumer system in order to control the energy supply of the at least one crane component.
In this case, the control unit regulates the energy requirement with regard to the required primary energy and / or secondary energy to be fed in, the energy utilization component requested by the drive motors of the crane components, and an energy storage component that can be stored in the at least one energy storage unit. In this case, it can be determined, for example, that additional energy requirement is always covered primarily from the at least one energy storage unit before the primary energy source is caused to generate new, additional primary energy. Thus, it is possible to avoid the generation of additional pollutant load and to reduce the fuel consumption. It is also possible to provide energy to certain crane components primarily, so that, for example, lifting or holding a load is always operated with priority over driving and / or pivoting or any other combined operation of the crane. In the event of a superlift operation of the crane, rocker jib luffing or jib pivoting associated with correction of the superlift mast is preferred to deflection and / or rotation or other combination. Further, turning on or off a counterweight car or controlling an activation of a counterweight system, as described for example in US 2009/0272708 A1, is preferred to a deflection and / or turning or other combined action of the crane. In addition, the crane function, which has to do most with the crane safety, z. As the maintenance of a secure geometry during lifting / lowering or relocation of the crane, always preferred over procedures of other crane functions.
A real-time condition monitoring of the crane is possible with the control of the crane according to an embodiment in which the crane further comprises a data bus enabling a two-directional data transfer. The data bus is connected to the control unit and also to the power consumer system to provide the control unit with electrical signals as input and output variables. The transmission and processing of electrical signals as input and output variables for the control unit is faster than mechanical, fluid-mechanical, pneumatic or electrical mechanical signals.
In a design of the primary energy source with a start-stop function, the primary energy source is designed such that it is activated when a start condition is met, and is deactivated when a stop condition is met. Thus, it is possible to design the required for the requirements for operating crane main functions such as a lifting device and / or a drive of the crane according to the primary energy source. By means of the start-stop function, operating hours of the primary energy source can be reduced by satisfying the stop condition of the primary energy source when, for example, neither the lifting device nor the traction drive are actuated. This reduces the fuel consumption for the primary energy source, which is designed in particular as a diesel engine. In addition, exhaust and noise emissions are reduced. Due to the reduced number of operating hours, the workload and the associated costs for the maintenance of the primary energy source are reduced.
In addition, the secondary energy source independent of the primary energy source can be provided for operating auxiliary components of the crane. Such auxiliary components may be, for example, an air conditioner, a cabin heater, a heater for the primary energy source, a generator, a hydraulic oil circulating pump for oil to be conveyed by an oil cooler, the oil cooler itself, or other components. The auxiliary components may be connected to the power consumer system so that they receive power only from the secondary power source. The fact that such auxiliary components can be supplied exclusively by the secondary energy source, the primary energy source can be decoupled from the auxiliary components. This makes it possible, in particular, for the stop condition for deactivating the primary energy source to be fulfilled more frequently and in particular over longer periods of time. In particular, the stop condition is fulfilled, and thus the primary energy source deactivated, if only auxiliary components, but not main components of the crane are operated. It is therefore not necessary for the diesel engine designed for the maximum power of the crane to be managed to be operated, for example to supply the air conditioning of the crane cabin with electricity. Due to the outsourcing of the power supply of the auxiliary components by the secondary energy source, the primary energy source can be smaller, i. H. with lower maximum available power. As a result, the required space in the crane and the weight for the primary energy source and thus for the crane are reduced overall. In addition, the fuel consumption in the ferry operation of the crane is reduced. It is therefore possible that the secondary energy source is in operation when the primary energy source is deactivated. Likewise, the secondary power source may be disabled when the primary power source is activated.
The secondary energy source may also be used to maintain the battery voltage to ensure sufficient energy for frequent engine starts of the primary energy source. In addition, the secondary energy source can have a motor generator so that the auxiliary components driven by the secondary energy source can additionally and / or alternatively be operated via a foreign energy source such as a 220 V power supply. The secondary energy source may be used to charge a hydraulic or pneumatic accumulator which, at the start of the primary energy source, operates an assisting engine, in particular a hydraulic or pneumatic motor, as an auxiliary starter.
A crane with a primary energy source allows a particularly uncomplicated handling and effective use of the crane, since the required fuel is available nationwide. In this embodiment, the primary energy source comprises an internal combustion engine, in particular a diesel engine, a transmission, which is connected to a clutch with the internal combustion engine, and a generator. An increase in the efficiency of the generator coupled to the internal combustion engine can be achieved by a self-cooling system located behind it, such as a heat exchanger in air or air cooling. It is also possible to supplement the internal combustion engine alternatively or additionally by fuel cells or by a connection to a network operation. In this case, emissions from the crane can be further reduced to operation, for example, without any CO 2 emissions.
In a crane with a crane component according to another embodiment, the energy fed into the power consumer system can be used in a particularly efficient and thus reduced-loss manner for the drive of the crane components. In this embodiment, the primary energy source comprises a diesel engine. Rotationally driven components, such as, for example, winches, slewing mechanisms or running gears, have proven particularly suitable because of the energy potential inherent in mass inertia and rotational energy in a large quantity. It is also possible to provide linear drives, for example by converting the electrical energy through a hydraulic system.
With an energy storage unit, it is possible to arrange a battery pack as a main energy storage centrally on the crane. For example, due to its high weight, the battery pack can be simultaneously arranged as a stackable counterweight on the crane as a base ballast or as a superlift counterweight on a counterweight truck separated by the crane. In this embodiment, the at least one crane component comprises a slewing gear or a hydraulic or electric linear drive, an energy converter and an electric motor. As a result, a usually separately required counterweight for the crane is unnecessary because the battery arrangement can be used as a counterweight.
The crane preferably has a secondary energy source which has a lower maximum available power compared to the primary energy source. Furthermore, the crane has a second energy storage unit, which is arranged centrally on the crane. Due to the correspondingly reduced requirements for the performance of the secondary energy source, this can be dimensioned correspondingly small and with lower power. This not least leads to a further weight saving of the crane as a whole.
It has been recognized that in addition to the primary energy provided by the primary energy source, recycled energy and other energy stored in the energy storage units should be available through the power consumer system.
Due to the large geometry of a large crane, d. H. Because of long boom and high lift heights, a crane with these features offers a great potential for traceable secondary energy. In particular, the energy saving potential of a crane is greater than that of an excavator or other construction machinery. Thus arise for a large crane according to the invention as a semi-hybrid or fully hybrid system a variety of options for energy supply, energy recovery and energy storage.
In a hybrid crane of the kind described herein, energy may be provided in the form of potential energy of the lifted load. Larger cranes, and in particular electrically powered cranes with long outriggers, are able to generate more energy from a movement of the load than cranes with smaller arms. This is because energy is generated by the downward movement of the load, and less energy can be gained from loads moving over short distances.
Energy recovery can be achieved by converting the potential energy of the boosted load into kinetic energy by lowering the load, for example, by generators into rotating winches, or by geometrically changing the crane, such as rocking the main and jib, by means of a pull-in hoist and a winch respectively. In addition, a total energy amount is provided which comprises the primary energy generated by the primary energy source and / or the secondary energy generated by the secondary energy source.
An energy share is the amount of energy required by the at least one crane component to operate it, and an energy storage percentage is the amount of excess energy generated by the crane's energy sources stored in the at least one energy storage unit. In this case, the total energy amount includes the energy use share and the energy storage share. The secondary energy is energy returned from crane operation. As a result, it is possible for the primary energy source to feed just as much primary energy into the energy distribution circuit as is actually necessary at the moment for operating the at least one crane component. A possible excess of the primary energy over the energy use portion is stored as an energy storage component in the at least one energy storage unit and is available for use at a different time or for a simultaneous use of other auxiliary functions on the crane. For example, batteries or double-layer capacitors, which are also known as ultracaps, can be used. With the present method, it is thus possible to reduce or avoid the idling operation of the crane, since the emission of pollutants by the primary energy source is always associated with a generation of an energy amount for the energy share. In the so-called limit load control, the energy share is determined as the total power required for all crane functions and crane movements. The fact that the crane components preferably have electric drives, this determination can be done quickly, directly and thus easier than in hydraulic drives.
For operating a crane with hybrid drive systems in intermittent operation other control characteristics are required than for the operation in continuous operation. Idling therefore means that energy is spent on operating the primary energy source without any real benefit associated with it. Thus, in idle, for example, no load is lifted or held, no load is shifted into position, no load moved, no load lowered or set down, and the crane is not moved.
Thus, it is possible to activate at least one crane component in a working mode of the crane, to deactivate the at least one crane component in an idling mode of the crane, and to control the crane operation so that in a suspension operation, the ratio of the operating time in the operating mode to the operating time in idle mode is not more than 0.3. It was recognized that the power supply of a crane in continuous operation can not be easily transferred to a crane operated in intermittent operation. In continuous operation, the crane is operated almost continuously under load, so that a permanent range of services for the operation of crane components is required. Accordingly, a primary energy source is operated continuously in continuous operation and the generated power demanded. The intermittent operation is characterized by the fact that a ratio of operating time during normal operation to idle operation is at most 30%, wherein at least one crane component, in particular at least one traction drive motor and / or at least one winch motor, is activated in the operating mode of the crane, and wherein in the idling mode of the crane, the at least one crane component is deactivated. The primary energy source is mainly operated at idle, since the crane performs the main functions of at least one crane component discontinuous and not in continuous operation. This means that in the intermittent operation of the crane components an amount of energy can be requested, which exceeds the currently generated amount of energy. Therefore, in addition to the amount of primary energy provided by the primary energy source, it is necessary to provide additional, secondary, secondary energy as well as other energy stored locally in the locally located energy storage units. The returned energy as well as the stored energy are available through the power consumer system.
A known power demand on the internal combustion engine can also be used for the load control of the internal combustion engine, so that no additional effort for the power requirement arises. This means that if the power demand is known, it is possible to use the appropriate power source, e.g. B. the internal combustion engine to control so that this known power requirement is provided. In particular, this energy source is controlled so that only this requested amount of energy and not more is provided. In this way, the internal combustion engine can be operated accurately with such a degree of utilization that the known power requirement is provided. Thus, it can be avoided to provide energy that is not needed in a current situation. In order to match the energy produced by the internal combustion engine with the known power requirement, the latter value can be used for the maximum load control of the internal combustion engine. Due to the fact that the crane components have electric drives and controllers with memory function, an expected power requirement can be calculated in advance by the crane components. It is thus possible to limit the power request by a maximum allowable maximum, so that the power request does not exceed the provided power. For example, this can be done by the maximum load control limiter. When a lift function is to be performed, the maximum load control limiter can calculate the energy demand to be provided within a predetermined period of time based on the lift height and the weight of the load. Since performance is defined as the quotient of labor expenditure per time, it is possible to influence the performance requirement by varying the time required to apply the performance demand, i.e., by varying the time required to perform the performance request. H. the greater the time required to apply the power request, the smaller the power requirement. This means that by increasing the time required to apply the power request, the power requirement can be reduced and thus limited to a maximum value. Furthermore, it can thus be avoided that the primary energy source, ie preferably a diesel engine, is loaded too heavily. Comparable anticipatory monitoring of a limit load on hydraulically driven crane components is not possible. Therefore, in conventional hydraulically operated crane components, in case of excessive power demand by the crane components, for example, the engine speed of the primary energy source drops, resulting in reduced speed of movement of the hydraulic components. In contrast, the use of electrically operated crane components in conjunction with the maximum load control discussed above can lead to a general improvement in the control characteristic for load limit control.
In a mooring operation, the electrical drives of the crane components can be operated speed-controlled or torque-controlled. These two operating conditions can be realized on the crane. The crane may therefore be provided with a means, such as a switch or menu selection, which allows the crane operator to switch between the two states. Thus, it is preferably possible to realize a proportional control or a speed specification for the Einscherhilfswinde when using a Einscherhilfswinde in variable speed operation. Thus, it is possible that can be switched to a torque-controlled operation of the crane components. For example, if the Einscherhilfswinde exerts a constant force, a corresponding counterforce is applied to another winch or other crane component. Thus, the variability of the use of Einscherhilfswinde is improved by appropriate control and can be adapted to the operating conditions accordingly.
[00104] In a method according to one embodiment, the energy share is provided either by conversion to electrical, hydraulic or mechanical energy of the at least one crane component for energy interrogation or fed to the power consumer system. More specifically, the energy share is provided by feeding into the power consumer system or via at least one energy converter connected to the at least one crane component to convert energy from the at least one crane component into power. Such a method has improved efficiency. The energy is provided in particular in the form of electrical energy decentralized at various points of the crane and can be decentralized accordingly without transmission losses directly to the energy source, in particular at the recovered secondary energy secondary energy source required. The regulation of the energy demand either via the power consumer system or directly to the crane component can be done by means of a control unit.
In a method according to one embodiment, it is ensured that in crane operation, a sufficient proportion of energy use is always made available either by the energy storage unit or the energy sources. More specifically, the method comprises the step of controlling the ratio of the energy use fraction to the energy storage fraction by means of the control unit.
A method according to an embodiment allows the calculation of an excess amount of energy, which is made available when a sum of the maximum usable energy use portion and a maximum usable energy storage component is equal to a sum of the excess energy and the total energy. This means that the amount of energy generated by the primary energy source and / or the secondary energy source is greater than the actual instantaneous energy demand and storable energy share.
By means of a method according to one embodiment, it is possible to reduce the excess energy portion controlled and convert, for example by means of additional braking resistors in heat energy. More specifically, the method further comprises a controlled reduction of the energy surplus component by converting energy, which is achieved by additional braking resistors, into thermal energy, whereby a return of the thermal energy to the crane can be used to heat a crane cabin. This heat energy can for example be returned to the crane and used in particular for heating the crane cab and hydraulic systems. As a result, an additional, separate heating of the crane cabin or the provision of a power source for the hydraulic systems can be avoided.
An exemplary embodiment is shown in FIG. A crane 1 is designed as a mobile crane with four wheels 2, wherein the crane 1 can also have more wheels 2 or, alternatively, crawler tracks (as shown, for example, in FIGS. 2 and 3). Of course, any other chassis can be used, which is within the skill of one of ordinary skill in the art. The crane 1 comprises an undercarriage 3 and a superstructure 5 rotatably mounted on the undercarriage 3 by means of a rotary feedthrough 4. At a front end of the undercarriage 3 in the direction of travel 6, a driving cab 7 is provided with a driving cab air conditioning system 8. Fixed to the superstructure 5 is a crane cab 9, which has a crane cabin air conditioning system 10. Rocking on the superstructure 5, a crane jib 11 is articulated.
According to the embodiment shown, a primary energy source 12 is accommodated in the undercarriage 3 of the crane 1. The primary energy source 12 is designed as a diesel engine and drives via a gear 13, the wheels 2; however, any other engine that is within the knowledge of one skilled in the art may be used. The transmission 13 is connected via a coupling, not shown, to the diesel engine 12 in a conventional manner. The diesel engine 12 is cooled by a cooler 14. Also directly to the diesel engine 12, at least one hydraulic pump 15 is connected, which is in signal communication by means of a hydraulic control line 16 with an undercarriage 3 arranged undercarriage control block 17 and arranged in the superstructure 5 overhead carriage control block. For this purpose, the hydraulic control line is guided by the undercarriage 3 in the superstructure 5 through the rotary feedthrough 4, so that the signal connection between the hydraulic pump 15 and superstructure control block 18 is not affected by a rotation of the upper carriage 5 on the undercarriage 3.
In addition, a control unit 120 is provided, which is connected to the primary energy source 12 and arranged adjacent thereto. The control unit 120 is activated by a crane operator in the crane cab 9. It is also possible for the control unit 120 to be actuated by the driver's cab 7. The control unit 120 and possibly additionally provided control units may be implemented as processors that control the various crane components of the crane 1. Such processors are known in the art. Software may be provided which is stored on a durable, non-transitory, computer-readable medium and executable by the processor to facilitate the various functions discussed herein.
The control unit 120 may have a start-stop function via which the primary energy source 12 is automatically activated as soon as a start condition is met, and deactivated when a stop condition is met.
Also connected to the primary energy source 12 is a cab air conditioning compressor 19 for operating the cab air conditioner 8. For this purpose, the cab air conditioning compressor 19 is connected to the cab air conditioner 8 via the cab air conditioning line 20 in signal connection.
Further, the primary power source 12 drives a primary power source generator 21 connected thereto through a power line 22 (i.e., a power consuming system) for charging a battery 23. Furthermore, at least one electrical load 24 is connected to the primary energy source generator 21, which is arranged according to the embodiment shown in the superstructure 5. It can also be provided a plurality of electrical consumers, which are arranged in the undercarriage 3 and / or in the superstructure 5 of the crane 1. As electrical loads 24, for example, lighting for the cabins 7, 9, a lighting of the crane environment, warning lights and warning signals, a crane control with display, a radio or other auxiliary consumers such as radios, mobile chargers u. a. be provided. In order to connect the primary energy source generator 21 to the at least one electrical consumer 24 arranged in the uppercarriage 5, the power line 22 is likewise guided through the rotary feedthrough 4.
In this embodiment, a secondary energy source 25 is provided in the uppercarriage 5, which is also used as an internal combustion engine, e.g. can be designed as a diesel engine. The secondary power source 25 may be realized by any suitable motor. The secondary energy source 25 is cooled by a secondary energy source cooler 26 which is in cooling connection via a cooling line 27 through the rotary feedthrough 4 to the radiator 14 arranged in the undercarriage 3. This makes it possible for the primary energy source 12 to be tempered by the secondary energy source 25 via the cooler 14 and / or the secondary energy source cooler 26 and the cooling line 27. For example, warmed cooling water from the secondary energy source cooler 26 can be conveyed from the secondary energy source 25 via the cooling line 27 into the cooler 14, and thus the primary energy source 12 can be preheated, so that a cold start can be avoided. The secondary energy source 25 drives an auxiliary source generator 28, which also feeds the battery 23 and the at least one electrical load 24 via the power line 22. Connected directly to the secondary energy source 25 is a crane cabin air conditioning compressor 29, which is connected to the crane cabin air conditioning system 10 via a crane cabin air conditioning line 30.
The secondary energy source 25 may be made smaller and less powerful than the primary energy source 12, wherein a maximum available power Ps.max of the secondary energy source 25 is less than a maximum available power Pp, max of the primary energy source 12, where Ps.max ^ 0, 5 · Pp, max, in particular Ps.max 5 0.3 · PP.max and in particular Ps.max ^ 0.1 Pp.max- This makes it possible to use a small motor as the secondary power source 25, since the maximum available power Ps, max is small. As a result, the energy consumption and also the emissions caused by the primary energy source 12 and the secondary energy source 25 can be reduced. Also, the space required for the secondary power source 25 on the crane is reduced.
The secondary energy source 25 may be retrofitted, so that the secondary energy source 25 by means of a correspondingly designed adapter receptacle (not shown) can be attached to the crane 1. The secondary energy source 25 is also referred to as additional unit. In particular, the secondary energy source 25 may also be embodied as one of the crane components, such as a luffing gear, a winch or, for example, a slewing gear for actuating the crane jib 11.
In the following, the function of the crane 1 according to the invention will be explained in more detail. In operation, the primary energy source 12 drives the traction drive, d. H. via the gear 13, the wheels 2 of the crane 1 at. Furthermore, the hydraulic pump 15 is driven by the primary energy source 12, which supplies the undercarriage control block 17 with pressurized oil. During a road trip takes the superstructure 5 no function. The secondary energy source 25 may then be deactivated.
As soon as the lifting device of the crane 1 is operated during the working operation, hydraulic oil is conveyed by the hydraulic pump 15 via the hydraulic control line 16 through the rotary carriage passage 4 into the uppercarriage control block 18. The lifting device consists of the upper carriage 5 and the crane boom 11. The superstructure control block 18 controls in conjunction with an electronic unit, not shown, in a conventional manner different crane movements such as the rotation of the superstructure 5 on the undercarriage 3 or a pivoting of the crane jib 11 In addition, the primary energy source 12 drives the primary energy source generator 21, which charges the battery 23 and supplies the at least one electrical load 24 with electrical voltage.
As mentioned above, during the working operation of the crane 1, a stop phase may occur during which no crane power is required, i. E. neither the superstructure 5, the boom 11 nor the traction drive (wheels 2 and gear 13) of the crane 1 are actuated. This stop phase is detected by the start-stop function of the control unit based on the stop condition, so that when one of the stop conditions listed below exemplified, the primary energy source 12 is deactivated.
For example, possible stop conditions are 1) no demand for hydraulic power, i. 2) presence of a battery voltage within predetermined limits by means of a battery voltage level indicator 112, 3) presence of a cooling water temperature of the primary energy source 12 within limits using a cooling water temperature gauge 113, 4) temperature of the pressure oil within limits by means of a pressure oil temperature gauge 114 and, 5) when only connected auxiliary components for exclusive power consumption from the secondary power source are turned on, and 6) further stop conditions individually by a user can be specified. These limits for the cooling water temperature are between 70 ° C and 95 ° C, in particular between 75 ° C and 93 ° C and in particular between 80 ° C and 92 ° C. The limits for the pressure oil temperature depend on the type of pressure oil used. For example, these limits are between 40 ° C and 80 ° C, and in particular at about 55 ° C. A load torque of the crane is detected. This detected load torque must be smaller than a defined Lastmomentschwellenwert, which z. B. at 30% relative to a maximum available load torque of the crane. The load torque is monitored periodically, regularly or constantly by means of a load torque limiting system (LMB), which is not shown in FIG. 1 but is implemented below. If the current load torque exceeds the load torque threshold, it must be made possible for the crane operator to promptly respond in steady crane operation for safety reasons. Therefore, the stop conditions are activated when the load torque exceeds the load torque threshold.
During a stop phase of the primary energy source, a number of functions may be required to fulfill the operation of auxiliary components of the crane 1 is required. Therefore, the following functions and / or auxiliary components are provided during the stop phases by secondary energy source 25 such as air conditioners 8, 10, cabin heating or heated engine cooling water and blower (not shown), temperature control of the primary energy source 12, for example via cooling water of the secondary energy source cooler 26 for Prevention of cold starts, power generation for electrical consumers such as lighting in cabins 7, 9, lighting of the crane environment, warning lights and warning signals, crane control with display, radio, auxiliary equipment such as two-way radios, mobile phone chargers, fans, oil cooler, oil circulation for cooling and filtering and maintenance the battery charge, as well as other functions and / or auxiliary components that may be provided in normal crane operation.
In addition, the secondary energy source 25 can drive further hydraulic pumps, not shown, which enable a control of the lifting device (superstructure 5 and / or boom 11) and / or winches or cylinders (not shown). As a result, an emergency operation can be made available with temporarily complete (or partial) failure of the primary energy source 12. Even regular crane movements are thus mobile with the secondary energy source 25, without the powerful primary energy source 12 must be started. Accordingly, depending on a maximum available power of the secondary power source 25, this power source 25 can be used as an additional drive without the primary power source 12 having to be started. Of course, as stated above, it is also possible to design the secondary energy source 25 as a low-capacity power source that provides only a small amount of the maximum available power. In this case, the secondary energy source 25 can not drive regular crane movements, but due to its small size it saves space and costs and also produces less emissions.
As a result of the realization of the start-stop function of the primary energy source 12 and the arrangement of the secondary energy source 25 independently of the primary energy source 12, as described above, standstill phases of the primary energy source 12 can be prolonged, thereby reducing fuel consumption, polluting emissions, in particular the CO 2 emissions. Emissions, reduced, reduced noise pollution, reduced wear of the corresponding components of the crane 1 and maintenance intervals for the primary energy source 12 are extended. The total weight of the crane 1 can also be reduced compared to a crane known in the prior art with powerful, separate superstructure motor for driving the crane hydraulics.
It is also possible to arrange the secondary power source 25 in the undercarriage 3 of the crane 1. Correspondingly, the secondary energy source cooler 26, the secondary energy source generator 28 and the crane cab air conditioning compressor 29 would also be provided in the undercarriage 3. With regard to the function of the crane 1, reference is made to the above-mentioned embodiments. In such a crane 1, the center of gravity is advantageously displaced downwards.
As a result, the stationary moment of the crane 1 is additionally increased.
It is also possible to arrange the primary energy source 12 together with the secondary energy source 25 in the uppercarriage 5 of the crane 1 or the primary energy source 12 in the uppercarriage 5 and the secondary energy source 25 in the lowercarriage 3 of the crane 1.
Figs. 2 and 3 show another embodiment of a crane 75. Components corresponding to those already explained above with reference to Fig. 1 bear the same reference numerals and will not be discussed again in detail.
The crane 75 is designed as a crawler crane with two parallel to the lower carriage 3 crawler tracks 76. Alternative arrangements of the crawler track or other chassis can also be used. Rotatable on the undercarriage 3, the superstructure 5 is arranged, which comprises the driving cab 7 and about a horizontal axis 77 (see FIG. 3) pivotable main boom 78. At one of the horizontal axis 77 opposite end of the main boom 78 this is also pivotally connected to an auxiliary boom 79. At the top of the jib 79, a bottle 80 is provided with a hook for lifting and shifting loads. The hoist rope 790 connects the jib 79 to the bottle 80. The main jib 78 and the jib 79 are braced by a tensioning system comprising a plurality of tensioning cables 81 and supports 82.
In the embodiment according to FIGS. 2 and 3, a counterweight arrangement 85 is provided on a substantially horizontally extending cross member 83 of the superstructure 5, spaced from a vertical axis of rotation 84 about which the superstructure 5 is rotatably mounted with respect to the undercarriage 3. The counterweight assembly 85 includes a plurality of stacked counterweights 86, wherein the counterweight assembly 85 may each have two laterally arranged on the cross member 83 stack (not shown) of individual counterweights 86. One of ordinary skill in the art may also provide other counterbalancing arrangements.
Also attached to the cross member 83 is the primary energy source, which may be in the form of a diesel engine 12 (or other suitable engine), and a primary energy source generator 21 connected thereto. At the the undercarriage 3 with the superstructure 5 connecting rotary feedthrough 4, a pivoting mechanism 46 is provided for pivoting the superstructure 5 about the axis of rotation 84. Each of the crawler tracks 76 of the undercarriage 3 is symmetrical with respect to the axis of rotation 84 and aligned and has a traction drive 58.
Also provided on the cross member 83 rotatable about a horizontal axis is a cable winch 43, which is connected via a cable to one of the supports 82. A telescopic cylinder 50 connects the main boom 78 with the cross member 83. By operating the telescopic cylinder 50 this is extended or extended and thus causes a pivoting movement of the main boom 78 about the horizontal axis 77. The telescopic cylinder 50 may be a hydraulic piston or similar mechanism.
In addition, a luffing mechanism 44 is provided on the cross member 83, which is connected via a tensioning cable 81 and the supports 82 with the auxiliary boom 79. Accordingly, the luffing mechanism 44 serves for pivoting the auxiliary boom 79 relative to the main boom 78.
The start-stop functions described above with respect to FIG. 1 may also be implemented in the crane 75 of the second embodiment. The start-stop function would be the same as in Fig. 1, so that a detailed description thereof is omitted.
Fig. 4 shows an exemplary embodiment of a schematic representation of an electrical circuit 300 of the crane 75. A power consumer system 31 comprises two power lines 32, one of which serves as a positive pole and the other as a negative pole. At the power consumer system 31, a voltage of 650 V is applied. Also as central supply lines cooling water hoses 33 are provided which serve for a forward and return line of cooling water. The power lines 32 are connected to various components to power them.
For controlling the power consumer system 31 is a control unit 34 via a data bus 35, which is designed in this embodiment, in particular as a CAN bus line, but also any other suitable, within the skill of a person skilled in the art can be used, connected. In the embodiment shown, the control unit 34 is connected via an interface 36 to the data bus 35. Thus, the control unit 34 is connected to the power consumption system 31 via the data bus 35, so that the control unit 34 is furthermore connected to all components that are directly and indirectly connected to the power consumption system 31.
For feeding primary energy into the power consumer system, the primary energy source 12, which may be provided in the form of the diesel engine, is connected by means of a clutch 37 to the transmission 13, via which two primary energy source generators 21 are driven. In the generators 21, the mechanical energy is converted into electrical energy and fed via the rectifier 38 in the power consumer system 31. Both the rectifier 38 and the primary energy source generators 21 are connected on the one hand to the cooling water lines 33 and on the other hand, and thus connected to the cooling water supply of the crane 1.
A control of the power consumer system 31 via the control unit 34 by an operator in the crane cab 9. It is also possible that the control unit 34 is additionally or alternatively operated from the cab 7, so that a control of the power consumer system 31 also from the cab is 7 guaranteed. Starting from the power consumer system 31, a large number of crane components (electrical consumers) can be supplied with energy, it being possible in principle to distinguish two different types of drive, namely rotary drives and linear drives.
The rotational components driven by rotary drives, e.g. Cable winches 43, luffing gears 44, derrick gear 45, a slewing gear 46 and a shearing winch 47 are connected via an inverter 39 to the power consumer system 31, the inverter 39 electric motors 40 provides electrical energy. The electric motors 40 drive consumer gear 41, which are connected via a brake 42 with the respective actual crane component 43-47. According to the exemplary embodiment shown, three cable winches 43, two luffing mechanisms 44, a derrick transmission 45, a swivel mechanism 46 and a shearing winch 47 are provided as crane components connected to brakes 42. Other crane components may also be connected or fewer brake components may be connected, as would be understood by one of ordinary skill in the art.
[00138] The linear actuators driven crane components, e.g. those driven by hydraulic cylinders are provided so that an electric motor 40 is also supplied with power via a converter 39 from the power consuming system 31. The electric motor 40 feeds a hydraulic pump 48. The hydraulic pump 48 serves as an energy converter for converting the electrical energy into hydraulic energy. Via a hydraulic distribution line 49 crane components are connected in the form of hydraulic cylinders. A telescopic cylinder 50 serves to extend and retract the telescopic main ram 78. Cabin cylinder 51 serve to tilt the cab 7 and / or the crane cab 9. To secure the crane boom 11 are locking cylinder 52 and to secure the superlift masts more locking cylinder 53 are provided. For a displacement of the superstructure, the cylinders 54 are provided. The cylinders 50 to 54 serve to supply electrical consumers 25, which are arranged on the superstructure 5. It is also conceivable to use an electric linear drive instead of the hydraulic cylinder.
In an analogous manner, the hydraulic pump 15 in the undercarriage 3 (shown in the embodiment of FIG. 1, but also visible in the embodiment of FIG. 2-3) is also connected to the power consumer system 31 via an inverter 39 and an electric motor 40 connected to convert the electrical energy of the power consumer system 31 into hydraulic energy and fed into the hydraulic distribution line 55. On the hydraulic distribution pipe 55 of the hydraulic pump 15, there are provided a quick-connection cylinder 56 and four support cylinders 57 for supporting the undercarriage 3, for example for enlarging or leveling the support base (not shown in the drawings) for the crane 1. The support base of the crane comprises a plurality of arms which are connected to the undercarriage drive of the crane 1, 75. Each boom is supported on the ground by at least one hydraulic cylinder mounted on a second end of the boom opposite the first end of the boom connected to the downcarriage 3. The hydraulic pump 15 allows storing a hydraulic fluid, such. As oil, which is why the hydraulic pump can be used as a secondary storage unit.
Also connected to the power consuming system 31 are traveling gears 58 in an embodiment in which the crane 75 is equipped with crawler tracks 76 (as shown in FIGS. 2 and 3) instead of the wheels 2 (embodiment of FIG. 1). It is possible to use decentralized drives, one for each of the wheels 2, to have a multiple drive. In this case, it is also possible to individually drive, brake and / or control the wheels 2, i. H. to control. Alternatively, it is also possible to provide a central control unit, a central brake system and also a central drive, so that some or all of the wheels 2 are operated and / or controlled simultaneously. It is also possible to provide a mixed configuration such that some of the wheels 2 are driven individually and a group of other wheels 2 are operated simultaneously by central drive systems, central brake systems and central control systems. In this case, each one of the travel drives 58 for the left and the right chassis 76 (only one of which is shown) is provided. Of course, other arrangements are conceivable for the average person skilled in the art.
The rotary mechanisms shown schematically in Fig. 4 as winches 43, luffing gears 44, derrick transmission 45, slewing gear 46 and shear 47 can serve as secondary energy sources. In this case, for example, by lowering the load, potential energy is converted into kinetic energy by the winches 43. By the rotation of the consumer gear 41, with the rotary mechanisms, z. B. the winches 43, are connected, a rotational movement of the respective transmission 41 is transmitted to the respective electric motor 40, which acts as a generator and converts the rotary motion into electrical energy and feeds them via the inverter 39 in the power consumer system 31. With a corresponding shearing of the hoist rope 79 in the bottle 80 is possible that even small strokes, d. H. only a small lowering of the load, causing a high number of winch turns. As a result, relatively high generator speeds can be made possible, so that a high efficiency in the energy conversion is possible.
In addition to the primary energy source 12 and the secondary energy sources 43 to 47, the possibility of an external power supply 59 is provided, which allows, for example, an injection of energy into the power consumer system 31. Thus, additionally or alternatively to the primary energy source 12 and the secondary energy sources 43 to 47 electrical energy can be used from a power grid. This makes it possible to operate the crane 1 independently of an internal combustion engine, which is deactivated, for example, in the presence of a stop condition.
The scheme shown in Fig. 4 of the power supply of the crane 1.75 is referred to as a decentralized system, since the individual consumers, d. H. the crane components, in each case separately via inverter 39, electric motor 40, consumer gear 41, brake 42 and a corresponding slewing gear 43 to 47 are connected to the power consumer system 31. Also, a central system of power supply is possible, in which a central switching unit is provided alternatively or additionally, to which the rotary mechanisms can be connected. The central switching unit 111 is shown in FIG. This central switching unit 111 converts the rotational movement of the rotating mechanisms into electrical energy, which is supplied as a secondary energy to the power consuming system 31. The advantage of the central solution is the reduction of the number of required inverter 39. Because the decentralized model without central switching unit 111 manages, however, the decentralized system is overall lighter in weight and more cost-effective, since in particular the costs for a switching unit 111 are higher as costs for additionally required converters.
Another advantage of the decentralized system is the integrated control in the crane components. Because the high, pulsed currents travel the shortest paths, i. H. without an intermediate switching unit, are fed into the respective electric motor 40 of the power consumer system 31, energy losses are reduced, thus improving the efficiency of the power supply. Overall, only two power lines 32 are needed in the crane 1, 75, which distribute the energy in the form of electrical energy to the crane components. The rotary feedthrough 4 between undercarriage 3 and superstructure 5 can be made smaller and therefore cheaper and more stable because of the reduced number of lines required. In particular, the rotary feedthrough 4 is less prone to failure in the decentralized system. Because of the reduced number of required power lines 32 and the required number of connectors for connecting the lines 32 is reduced. This is realized for both the first and the second embodiment.
Furthermore, in both exemplary embodiments, an energy storage unit 60 is connected to the power consumer system 31 (see FIG. 6). The energy storage unit 60 is centrally provided on the crane as a main energy storage and is designed for example as a battery pack. This battery pack may preferably be arranged as a stackable counterweight on the crane 1, 75 as a basic ballast or as a superlift counterweight on a separate counterweight car. At least one fuel cell 110 is connected to the power consumer system 31 (see FIGS. 4, 6). The fuel cells 110 power the power consumer system 31 when needed.
In addition, a plurality of decentralized energy storage units are provided on the crane 1, 75, which are connected to the power consumer system 31 and serve to store primary energy and / or secondary energy. For example, a winch with a decentralized energy storage unit may be provided on a winch frame. In one embodiment, the energy storage units may in particular be directly associated with the crane components in order to reduce transmission losses and thus to improve the efficiency of the system.
Also connected to the power consumer system 31 is the on-board network 61. The electrical system 61 is a power connection which ranges from 12 V to 400 V. This power connection can be z. B. for heating the cabins 7, 9, a hydraulic heater, a radio, etc. are used. Consequently, the power connection can be regarded as an auxiliary connection. Alternatively, the above-executed auxiliary components, such as. As battery packs and / or fuel cells, not intended as auxiliary configurations, but as basic configurations of additional energy providers.
In Fig. 6, a flow for controlling an energy balance of the crane 75 is shown schematically. Fig. 7 also shows a flow chart of the determination of various amounts of energy in the crane system. A similar circuit diagram can be shown for the crane 1 shown in the embodiment of FIG. 1 or the crane 87 shown in the embodiment of FIGS. 2 and 3. Once the crane's crane components have been identified, its configuration is the responsibility of the average person skilled in the art. The primary energy source 12 as well as the usable as secondary energy sources crane components 43, 44, 45, 46, 47 are connected to the power consumer system 31 for feeding primary or secondary energy in signal connection. Furthermore, the external power supply 59 may be provided for an alternative supply of external energy. The total energy 121 is the sum of the energy fraction amounts fed into the power consuming system 31 from the power sources 12, 43 to 47 and 59. One part of this, the so-called energy use share 122, is requested for operation from the crane components 43 to 47, 51 to 54. For this purpose, the crane components 43 to 47, 51 to 54 are in signal communication with the control unit 34. A Lastmomentbegrenzer 115 (LMB) is integrated into the control unit 34 and allows the energy giemanagement the cranes 1.75 and 87. Thus it is the control unit 34, for each individual crane component 43 to 47, 51 to 54 a current and / or z. B. due to a planned lifting movement or other movement of the component by a comparator 123 in the control unit 34 to be expected Energieutzanteil 122 to determine. As a result of the comparison made by the comparator 123, it is possible to decide whether there is a first case 124 in which the total energy amount 121 is greater than the total energy use portion 122, or if there is a second case 125 in which the total energy amount 121 is less than or equal to the total energy use ratio is 122. The total energy use portion 122 of the crane 75 is equal to the sum of all energy sharing portions of the crane components 43-47, 51-54 and the energy use portion of the traction drive 58. When the amount of energy fed into the power consuming system 31 exceeds the current energy share, i. If more energy is produced than is currently required by the various components, the excess portion is transferred as a so-called energy storage component 126 from the power consumer system 31 into the energy storage unit 60 and / or the at least one fuel cell 110 (not shown in FIG. 7, see FIG 6). For this purpose, the power consumer system 31 is in signal connection with the energy storage unit 60 and the at least one fuel cell 110. If the energy storage unit 60 can not absorb any further energy, for. For example, if the energy storage unit 60 has a fully charged battery and excess energy is provided by the power sources 12, 43-47, this excess energy portion may be transferred to the external power supply 59 and / or to the crane 75 itself, e.g. B. as electrical energy for operating an electric heater in the crane cab 9 or as heat energy, for. B. as heated air by means of a heating tube to the crane cabin 9. The same process occurs when the at least one fuel cell 110 is fully charged. The energy surplus can also be fed back to the external energy supply 59 as electrical energy.
The control unit 34 allows the monitoring of the individual Energieutzanteile the crane components 43 to 47 and 58. Further, the control unit 34 allows the monitoring of the energy sources 12, 43 to 47 and 59 fed amounts of energy. In addition, the energy storage component in the energy storage unit 60 is also monitored by the control unit 34. By means of these monitoring functions, the control unit 34 enables an effective, fast and direct energy management of the crane 75. The control of the crane components is carried out by an operator in the crane cabin 9 via the central control unit 34 or the driver's cab 7.
In the following, a winch 43 will be explained in more detail with reference to FIG. The winch 43 is shown in a longitudinal section parallel to a rotation axis 62. The cable winch 43 is fixedly mounted on the crane 1 or 75 with a motor-side winch holder 63 and a gear-side winch holder 64. Between the winch holders 63, 64, a sheet metal trough 65 is provided which serves on the one hand to stabilize the winch attachment and on the other hand also for attachment of the winch 43rd can be used on crane 1 or 75.
Concentric with the axis of rotation 62 of the electric motor 40 is arranged, which can be designed as a torque motor. Other motors within the skill of the art may also be used. The fact that the electric motor 40 is integrated in the cable winch 43 in this embodiment, an additional space requirement on the crane 1 or 75 is reduced. This makes it possible to build the crane 1 or 75 smaller overall. The electric motor 40 is rotatably held on the motor-side winch holder 63 and rotatably connected to a cable drum 68 of the cable winch 43 via a sleeve 66 and a rolling bearing 67, which may be designed as a floating bearing about the axis of rotation 62. The cable drum 68 is also arranged concentrically to the axis of rotation 62 and is designed as a hollow cylinder. The motor 40 is disposed within the cable drum 68 and thus can be arranged in a particularly space-saving manner on the crane 1 or 75.
According to one embodiment, the cable drum 68 has an inner diameter D, of about 540 mm and thus offers enough space for a commercially available torque motor.
On an outer circumferential surface of the cable drum 68 guide grooves 69 are provided for the rope to be wound. At the end faces of the cable drum 68 are each substantially radially away from the cable drum 68 wegerstreckende plate 70 is provided, which serve for guiding and holding the wound rope.
The motor 40 further has a continuous drive shaft 71, which is arranged concentrically to the axis of rotation 62. The drive shaft 71 is rotatably connected to the motor 40 and guided guided in a fixed planetary holder 73, which acts as a fixed bearing. The drive shaft transmits drive torque to a rotating transmission case 72 and drives it. The gear housing 72 is rotatably connected to the cable drum 68 and thus ensures a torque transmission from the motor 40 via the drive shaft 71 and the gear housing 72 on the cable drum 68th
At the transmission-side winch holder 64, the brake 42 is provided via an adapter flange 74, which is fixedly secured to the adapter flange 74. The brake 42 may be designed as a solenoid spring-loaded multi-disc brake.
Thus, on the one hand, it is possible to drive the cable winch via the electric motor 40 and the gear 73 in order, for example, to wind a cable onto the cable drum 68 and a load to raise. However, it is also possible, when lowering a load, to drive the electric motor 40 via the transmission and the drive shaft 71 and to use it as a generator for the purpose of electrical power generation. In addition, the brake 42 serves to avoid, for example, a departure of the load or too fast rotational movement of the cable drum 68 for safety reasons.
Fig. 10 shows an exemplary embodiment of another embodiment of a crane 87. Components corresponding to those already explained above with reference to Figs. 1 to 9 bear the same reference numerals and will not be discussed again in detail.
Significant difference of the crane 87 over the crane 75 shown in Figs. 2 and 3 is the design as a superlift crane with a superlift pole 88. Further, a counterweight car 92 is connected to the upper car 5 of the crane 87, with an additional Counterweight 93 is arranged separately from the upper car 5 on the counterweight car 92.
Based on sensors schematically illustrated in FIG. 10, a procedure is described below by means of which an operator can shift a load both horizontally and vertically (not shown). The energy utilization component required to operate the relevant crane components is provided by the winches 43 and / or the luffing mechanisms 44. For this purpose, the operator prescribes a desired change in the load position or a crane position via the operator interface 107 connected to the control unit 34 (not shown in FIG. 9, see FIG. 8). The control unit 34 calculates various energy parameters that relate to the respective energy requirements of crane components of the crane 87. For this purpose, from current data of force sensors 89, 90, 91 on the jib 79, the main boom 78 and superlift mast 88 of angle encoders 94, 95, 96 on the jib 79, the main boom 78 and the superlift mast 88th , the height of the load, which is determined from the crane geometry and rotary encoders 97, 98, 99 of the winches 43, the luffing gear 44 and a hoist 100, of length encoders 101, 102 for adjusting the superlift mast 88 and the counterweight 92, respectively and determined by the state of charge of the energy storage unit, not shown, energy contents of the individual crane components for the entire crane 87 and transmitted to the control unit. These data of the energy charging condition are displayed and therefore, as shown in FIG. 4, can be monitored by the user interface 107. Based on these data, control unit 34 proposes possible and energetically favorable control movements and in particular their sequence. For example, it is possible to define a starting point and a destination point of the load to be conveyed. Taking into account at least one obstacle, a virtual connecting line between the starting point and the destination point can be subdivided into a sequence of vertical and horizontal movements. Starting at the starting point, a maximum vertical upward movement is first calculated. Thereafter, a sequence of horizontal movements in a horizontal plane parallel to the ground is provided, in particular over the at least one obstacle. In a final step, the load is lowered to the destination point. Of course, other path calculations are possible, such as a direct line calculation, i. H. the shortest connection between the starting point and the destination point.
The concrete implementation of the crane movement to shift the load can then be done by the operator by operating various control transmitter for the individual crane functions. As a result, in particular the risk of accidents and / or malfunctions, for example due to deviating operations, local conditions in the form of interference edges or safety issues will be reduced.
Furthermore, by recognizing energy requirements and creating the respective power potential of the crane components, the operator can directly influence the energy management of the crane 1, 75, 87. For example, he may weigh whether or not to relocate the load without activating the primary energy source 12. In addition, it is possible with the energy management system to consider the individual efficiencies of the respective crane components. Since, for example, a crawler undercarriage 76 has a lower efficiency than a cable winch 43, a lower required proportion of energy consumption at the cable winch 43 would be required via the control unit 34 in order to reduce the energy loss. For example, if it is intended to raise a load of known weight to a known height, the control unit 34 may calculate the amount of potential energy that must be provided for such lift action. Based on this data, the control unit 34 may also calculate a required amount of energy. Accordingly, the energy saving potential is further improved.
It is also possible that the load initially calculated by the control unit and, if desired, simulated displacement of the load takes place automatically, i. E. The operator does not intervene in the relocation process of the load. In this case, parameters such as load radius, load height, ballast position, superstructure position and / or traversing position of undercarriage 3 or counterweight 92 are calculated according to an energetically favorable load transfer scenario. Safety-related boundary conditions can also be included in the calculation in order to reduce the risk of collision when shifting the load. In particular, for the autonomous implementation of the load transfer in the embodiment of FIG. 10 advantageously an angle sensor 105 on the upper carriage 5 for detecting the angular position of the upper wagon and alternatively or in addition to the Längengebern 101 a pressure transducer 109 for determining the angular position of a rotation axis 108 of the Superlift mast 88 are used, whereas the axis of rotation 108 is perpendicular to the axis of rotation 84. The angle sensor 105 and the pressure transducer 109 forward the determined positions to the control unit 34, which uses these to control the autonomous displacement. According to the pressure in the pressure transducer 109, a particular position of the super lift mast 88 can be calculated because the pressure in the pressure transducer 109 is proportional to an angular position of the super lift mast 88 relative to the axis of rotation 108.
A crane 1, 75, 87 according to the embodiments shown thus allows savings in energy consumption and emissions in particular in intermittent operation, which characterizes the usual operation of a lifting device as in the cranes 1, 75, 87 shown here. In order to improve the efficiency of the primary energy source 12 in the form of the internal combustion engine, a self-cooling system such as a heat exchanger to the air or air cooling may be provided. This self-cooling system is connected directly to the primary energy source 12, so that heat can be dissipated from the primary energy source 12. For this purpose, it is known that a cooler, z. As a heat exchanger, connected directly to the primary energy source 12 and is arranged in its immediate vicinity. To further reduce pollutants and the consumption of fossil fuels, it is possible to replace the internal combustion engine by fuel cells or, for example, when operating the stop function to operate the power consumer system 31 in network operation, d. H. to use the external power supply 59, or to use energy stored in the at least one energy storage unit 60. For this purpose, the control unit 34 can serve, for example, the current Energieutzanteil, but also the current energy storage component of the energy system detected and evaluated. The current share of energy use is the proportion of the total amount of energy used by the crane components at a given time. The current energy storage component is the proportion of the total energy amount that is stored in the at least one energy storage unit 60 at a specific time. Both the energy storage component and the energy use component can be calculated or measured by the control unit 34.
By using the electric motors 40 instead of hydraulic drives, it is possible to achieve higher partial efficiencies on the crane and thus to improve the overall efficiency of the crane as a whole. In addition, downtime of the crane 1 can be reduced. Since the partial efficiencies are higher when using the electric motors 40 instead of hydraulic drives, it is possible to provide the same amount of energy with a shorter operating life of the electric motors 40. Thereby, the overall requirement of the electric motors 40 is reduced, so that downtime for the repair, maintenance and / or replacement of the electric motors 40 are reduced. Overall, the energy supply of the crane 1 shown thus takes place diesel-electrically with one or more generators 21, preferably synchronous generators, each having a converter 39, d. H. a frequency converter, electrical energy, d. H. Feed primary energy into the power consumer system 31. The motors 40 are preferably synchronous motors and are powered from the power consuming system 31. Because in particular a plurality of energy storage units 60 are connected to the power consumer system 31, it is possible to realize a short-term storage of excess energy, ie the energy storage component, and thus to realize a short-term high power consumption from the power consumer system 31. In the event that the energy total to be fed into the power consumer system 31 is greater than the sum of the energy use component and the energy storage component, the excess energy component can be reduced with additional braking resistors and converted in the form of thermal energy. In principle, it is also possible to return this excess energy via the generators 21 to the internal combustion engine 12 during engine operation. The internal combustion engine could then dissipate the energy, for example in overrun mode and possibly with additional braking devices such as damper brake or constant throttle. As shown in Fig. 4, the control unit 34 is centrally located in the crane. It is also possible that a plurality of control units are provided, the decentralized on the crane, d. H. are arranged on the crane components.
The main advantages of this drive system are that you can simultaneously use all crane components, taking into account a maximum available power, independently and directly controllable. Furthermore, it is possible to determine the drive power of the individual crane components directly. In addition, it is possible to limit the drive power of the individual components and thus to limit the total power consumption of the crane. This could be realized, for example, by the control unit 34, whereas a drive power limit of the individual components is calculated on the basis of a maximum rotational speed of these components. In addition, it is possible to evaluate all drives of the crane components with regard to their current energy status, their use and the operating time. Since all drives of the crane components are connected to the control unit 34 and these drives include corresponding sensors that allow the control unit 34, a current position and also a current speed of movement of the drive, for. As a rotational speed or a transverse speed to determine, it is possible to determine the current energy state of these components. Furthermore, use and the operating time of these components can also be determined by the control unit 34. This enables a direct and simple load collective determination and a real-time condition monitoring, so that critical conditions of the crane components can be detected early and possible failures can be avoided if necessary. As a result, downtimes can be reduced and inherent energy states can be determined. In the event that the crane is connected to the external power supply 59, it is possible to operate the crane emission-free.
In such a crane, its overall availability is improved, thereby increasing the useful life for an operator. Because the crane components are only used when it is really necessary, and their use is also adjusted to the maximum performance requirements of the crane components, which means that the crane components are not operated at maximum power for an extended period of time, which could lead to premature failure of these components, increases the efficiency of the crane. Four different modes of operation are available, namely a standby mode 117, a half hybrid mode 118, a full hybrid mode 119, and a full electric mode 120. As shown schematically in a flow chart in FIG. 8, it is in operation Cranes possible to switch between these four operating states. For example, the crane operator can select one of these states directly via the operator interface 107. The operator interface 107 generates a decision signal 116, depending on which state has been selected. For this purpose, the user interface 107 is connected directly or alternatively via the control unit 34 to the power consumer system 31. Thus, it is possible to display the current energy management situation of the crane 1, 75 or 87, so that the crane operator can decide which of the four operating conditions is the best for the current situation. Alternatively, it is also possible for this best state to be measured by the control unit 34 based on current signals of the power consumer system 31 and the crane components 9, 12, 43, 44, 45, 46, 47, 51, 52, 53, 54, 58 and 59 attached thereto is calculated. With this approach, the selection of the best operating condition is automatic and therefore ensures effective and economical operation of the crane, even if the crane operator does not monitor the operation of the crane all the time. Furthermore, the operator interface 107 activates the crane operator during the mooring operation, whether the electrical drives of the crane components 9, 12, 43, 44, 45, 46, 47, 51, 52, 53, 54, 58 and 59 by the control of the rotational speed 127th , or operated by the regulation of the torque 128. Such a change of the operating modes of the control of the electric drives is usually decided by the crane operator. It is also possible to develop decision rules that are stored in the control unit 34 so that, depending on a current charging situation and based on these decision rules, the control unit 34 for selecting one of the operating modes 127, 128 can send a switching signal via the user interface 107 ,
In standby mode, various auxiliary functions, in particular electric drives, can also be activated during a stop function by the secondary energy source even when the primary energy source 12 is deactivated. In semi-hybrid mode, for example, both the primary energy source as an internal combustion engine and the electric drives for the at least one crane component are used in addition to energy for operating the crane. In full hybrid mode, energy reserves from the energy storage units or electrical energy of the secondary energy sources are used in preference to the energy supplied by the primary energy source. The primary energy source is required, especially in the presence of the start-stop function due to the suspension operation of the crane only very rarely, and even in the activated state of the primary energy source unused energy is not lost, but is stored by the energy storage units. In full electric mode, only electrical energy sources, i. H. Fuel cells, photovoltaic systems and / or batteries used as energy storage units or network operation. As a result, pollutant emissions and thus noise emissions are completely avoided.
The combination of the four operating modes mentioned ensures that the crane is available at a higher capacity, ie. H. even if one power source fails, the crane can switch to one of the other operating modes. A switching of the operating modes, for example, may also be required if, for example, the internal combustion engine must be deactivated due to emission regulations or the external power supply network is no longer available. Also, it is not necessary to operate the crane at a constant load or, for example, to shut down the crane altogether if the stop condition is met. As a result, the life of the crane main components is increased and not least, the resale value of the crane can be increased. Switching between the operating modes can be done, for example, via the control unit 34, which can either automatically determine the operating mode to be used or can be instructed by operating a switch or selecting a menu item by the crane operator to switch between the operating modes.
The additional provision of several, simultaneously operating safety devices such as a load torque limiting system (LMB) 115 improves the safety of the disclosed cranes and detects crane geometry, system inherent forces and thus latent energy potentials.
The LMB 115 is an integral part of the control unit 34 and shown schematically in Fig. 6. As is known, monitor the LMB 115 the current load torque and guaranteed by actively influencing relevant parameters such as load height and load radius by driving appropriate crane components that a known maximum value for the Load torque is not exceeded. The fact that the LMB 115 determines the current safety situation of the crane, information regarding the crane configuration, z. In relation to the loads, the pressures in the hydraulic or pneumatic cylinders, the hook and the load height, and the energy potentials that could be obtained from each of the crane components are directly detected and provided as electrical signals. These electrical signals are displayed to the crane operator by means of the user interface 107. It is also possible to use the electrical signals as control signals in the control unit 34 in order to transfer the energy potentials as a parameter for the control unit 34. The energy potentials thus represent available energy reserves that can be recorded via the LMB 115. As a result, possible energy requirements are determined and possible operating speeds are predicted via the energy storage units. Above all, however, the LMB 115 allows sensitive operation of the crane components, which is accomplished by redundant LMB control systems, which take into account the three degrees of freedom of the floating load, determined in real time and fed directly to the control unit as an electrical control variable.
With the real-time condition monitoring, it is possible to query load cycles, torques and loads at different points of the crane easily and directly and to use for further information processing. The loads at all detected points of the crane are summed to determine and monitor a current maximum load of the crane. The real-time condition monitoring is made possible by the input and output signals electrically provided by the various sensors to the control units, which guarantee fast data processing and communication. In conjunction with the crane loads determined by means of the LMB 115, monitoring of the crane components is thus achieved. For example, it is possible that a not fully open brake or a stiff bearing is detected by an excessive power consumption of the corresponding crane component. The need for repairs is thus easy to determine and to quickly improve the crane movements and safety.
The prerequisite for real-time condition monitoring of the crane is thus the provision of the control variables as electrical variables of the various LMB 115 and other sensors, so that they can be processed quickly. Appropriate energy management makes it possible, on the one hand, to present the energy balance of the crane in real time and thus to improve energy savings and, on the other, to set priorities for the management of all energy producers and consumers. For this purpose, an LMB system is used, which is equipped with electrical, fail-safe and redundant sensors for autonomous control of sections of the crane. This makes it possible to relieve the crane operator as areas of the crane are controlled automatically by decentralized, highly autonomous controls in the form of intelligent systems. This can be done, for example, by tracing the respective crane geometry or raising and lowering loads in the event of visual obstruction such as fog by means of the control unit 34. Regulations that are not realized in real time are not suitable for the automatic control of crane tasks due to the safety risk.
Another advantage of the use of electrical control variables over mechanical or fluid mechanical control variables is the avoidance of transformation losses and thus of signal distortions in the signal conversion.
It should be understood that while various features of the invention have been described in connection with particular embodiments, it would be possible for one of ordinary skill in the art to combine these features in other embodiments not shown in the figures.
The aim of the foregoing description is to depict the general nature of the invention so that others may, by the use of the present state of knowledge, readily vary and / or adapt these particular embodiments without undue experimentation and departure from the scope of the appended claims. These adaptations and changes should and can therefore be considered as similar to the embodiments disclosed herein. Of course, the phraseology or terminology used in this disclosure has a descriptive and not a limiting character.
The means, materials and steps used to perform various disclosed functions may be in many different forms without departing from the invention as described in the appended claims. By the terms "means to ..." or "means for ...", or by any other term referring to method steps in the foregoing description and / or the following claims in connection with a functional statement, all structural, physical , chemical or electrical elements or structures, as well as all process steps that are available now or in the future for the performance of said function, even if not completely synonymous with the embodiment (s) disclosed in the foregoing description ie Other means or steps to perform the same functions may be used. Furthermore, these terms are to be interpreted according to their broadest field of meaning, without this resulting in a deviation from the scope of the appended claims.

权利要求:
Claims (14)
[1]
claims
A crane (1) comprising a power consumer system (22) for providing power, a primary energy source (12) for injecting primary energy into the power consumer system, at least one secondary energy source (25) independently controllable from the primary energy source for injecting secondary energy into the power consumer system, wherein the secondary energy source is connected to the power consumer system and configured to at least partially recycle energy derived from the operation of the at least one secondary source into the power consumer system as a secondary energy, wherein the secondary power source comprises at least one crane component, at least one connected to the power consumer system and distributed to the crane arranged energy storage unit (23) for storing primary energy and / or secondary energy, wherein the crane is associated with at least one crane component, at least one of the Leistungsverbra uchersystem connected drive motor (40) for operating the at least one crane component in response to an input into the power consumer system energy, and a control unit, which is for controlling the power supply of the at least one crane component with the power consumer system, the primary energy source and the at least one secondary energy source in signal communication, characterized in that the control unit (120) comprises a non-transitory computer-readable medium having stored software for performing the steps of: providing a total energy amount (121) comprising primary energy generated by the primary energy source and / or generated by the at least one secondary energy source Secondary energy, calculating an energy usage component (122) requested by the at least one crane component, storing an energy storage component (126) in the at least one energy storage unit, and Providing the energy share for the at least one crane component via the power of the at least one energy converter, the total energy amount comprising the energy share and the energy storage portion, and wherein the secondary energy is energy returned from the operations performed by the at least one crane component, the crane further including at least one the at least one crane component connected energy converter for converting energy from the at least one crane component into power, and the control unit regulates a ratio of energy use share to energy storage component.
[2]
2. Crane according to claim 1, characterized by a data bus (35), which allows a two-dimentional data transfer, wherein the data bus is connected to the control unit and also to the power consumer unit to supply the control unit with electrical input and output variables, and wherein in particular in an emergency operation, the control unit is designed to ensure the supply of energy to the crane from the secondary energy source, and wherein the crane further comprises a particular connected to the superstructure angle sensor for detecting and transmitting an angular position of the upper carriage to the control unit.
[3]
A crane according to claim 1, comprising auxiliary components connected to the power consuming system (31) for receiving power exclusively from the secondary power source.
[4]
4. Crane according to claim 1, wherein the at least one crane component comprises a slewing gear or a hydraulic or electric linear drive, an energy converter (39) and an electric motor, wherein the energy converter in particular comprises a consumer gear or a hydraulic pump.
[5]
5. The crane according to claim 1, comprising at least one power consumer connected to the power consumer system (21), the system supplying the at least one power consumer with energy from the primary energy source and / or from the at least one secondary energy source (25).
[6]
A crane according to claim 1, further comprising: an undercarriage (3), a superstructure (5) rotatably mounted on the undercarriage, a hydraulic pump (15), a plurality of connected hydraulic cylinders for supporting the undercarriage, a converter (39), a hydraulic motor connected to the hydraulic pump, the converter and the power consumption system (31) for converting power from the power consuming system into hydraulic energy to be used to control the positioning of the undercarriage of the hydraulic pump, the crane further comprising: a superlift mast ( 78) on the uppercarriage, a pressure transmitter connected to the Superlift mast to detect and transmit an angular position of the Superlift mast to a control device.
[7]
A crane according to claim 1, comprising an external power supply adapted to supply mains power to the power consumer system (31).
[8]
8. The crane according to claim 1, wherein the at least one crane component comprises at least one slewing gear and the crane further comprises a central switching unit, which is connected to the at least one slewing gear and the power consumer system (31) for converting the rotational movement of the at least one slewing gear into electrical Energy to be supplied as a secondary energy to the power consumer system, and wherein the power consumer system in particular comprises two power lines.
[9]
A crane according to claim 1, comprising a second energy storage unit centrally disposed on the crane for storing excess energy from the primary energy source and / or the secondary energy source (25), the second energy storage unit comprising in particular a battery assembly serving as a stackable counterweight on the Crane is arranged, wherein the second energy storage unit comprises in particular a battery assembly which is arranged as a super-lift counterweight on a counterweight car separate from the crane.
[10]
10. The crane of claim 1, wherein the software is capable of performing the following step of providing power to maintain the energy share from the energy storage unit in preference to energy supplied from the primary energy source, wherein the software includes, in particular for controlling the power supply to certain crane components in preference to other crane elements, wherein the software in particular performs the following steps: activating at least one crane component in a working operation of the crane; Deactivating the at least one crane component in an idle mode of the crane, and controlling the crane operation such that at a intermittent operation, a ratio of the operating time in the operating mode to the operating time in idle mode is at most 0.3, the software in particular the step of providing the energy use portion of the at least performs a crane component by causing a feed of energy into the power consumer system, wherein the control unit calculates in particular an excess amount of energy, so that a sum of the energy use portion and a maximum energy storage portion equal to a sum of the excess energy portion and the total energy amount, the control unit in particular a Reduction of the excess amount of energy caused by conversion of the energy obtained from additional braking resistors in heat energy, with a return of the heat energy to the crane to In particular, the software executes the following step of providing power to maintain the energy share from the energy storage unit in preference to energy supplied from the primary energy source, the software particularly including the step of controlling the power supply certain crane components in preference to other specific crane elements.
[11]
A crane according to claim 1, wherein said control unit (120) is capable of controlling crane operation in optionally four modes of operation, said four modes of operation being a standby mode, a half hybrid mode, a full hybrid mode and a full electric Mode, wherein in the standby mode at least one auxiliary function can be activated by the secondary energy source when the primary energy source is deactivated, in particular in the half-hybrid mode both the primary energy source and the electric drives for the at least one crane component be used to generate energy for operating the crane, in particular in full-hybrid mode energy reserves from the energy storage units or electrical energy of the secondary energy sources are primarily used before energy from the primary energy source to operate the crane, wherein in full electric mode in particular exclusively electrical energy sources z be used to operate the crane, in particular comprising an operator interface that allows a crane operator to change between the four modes of operation, the control unit comprises in particular a module that automatically detects which of the four operating modes should be used, and the control unit to do so causes to switch to the predetermined mode.
[12]
12. A method of operating a crane, the method comprising: activating at least one crane component in a working mode of the crane (1); Deactivating the at least one crane component in an idle mode of the crane; Control of the crane operation such that in a suspension operation, a ratio of the operating time in the working mode to the operating time in idling mode is at most 0.3; Providing a total energy amount (121) comprising a primary energy generated by the primary energy source and / or a secondary energy generated by the at least one secondary energy source, calculating an energy use fraction (122) requested by the at least one crane component, the at least one crane component being configured as a secondary energy source for energy recovery and locally storing an energy storage portion (126) in the at least one locally disposed energy storage unit, wherein the total energy amount comprises the energy usage portion and the energy storage portion, and wherein the secondary energy is energy derived from operations of the at least one crane component, characterized by providing the energy usage portion for the at least one a crane component by means of feeding energy into the power consumer system; a provision of the energy use component for the at least one crane component by means of the at least one energy converter connected to the at least one crane component for converting energy from the operation of the at least one crane component into power, a regulation of a ratio of energy utilization component to energy storage component by means of a control unit; a calculation of an energy surplus share by means of the control unit such that a sum of energy use share and maximum energy storage is equal to a sum of energy surplus share and energy total, and a controlled reduction of the energy surplus share by converting energy obtained from additional braking resistors in heat energy, wherein a return of the heat energy to the Crane is done in particular for heating a crane cab.
[13]
13. The method of claim 12, further comprising: providing power to at least one crane component via a power consumer system, injecting primary energy into the power consumer system using a primary energy source, operating the at least one crane component via at least one motor connected to the power consumer system, injecting Secondary energy in the power consumer system by returning the secondary energy from the operation of the at least one crane component as a secondary energy source (25), which is independently controlled from the primary energy source, and storage of the primary energy and / or the secondary energy by means of at least one decentralized arranged on the crane and to the power consumer system connected energy storage unit.
[14]
14. The method according to claim 12, wherein the crane comprises at least one crane component, a primary energy source, at least one secondary energy source and a power consumer system connected to the at least one crane component, the primary energy source and the at least one secondary energy source for supplying the at least one crane component with energy The primary energy source and / or the at least one secondary energy source (25), the method comprising the steps of: providing a total energy amount comprising one of the primary energy generated by the primary energy source and / or a secondary energy generated by the at least one secondary energy source, calculating one of the at least one crane component requested Energieutzanteils (122), and storing an energy storage component in the at least one energy storage unit, wherein the total energy amount includes the energy use portion and the energy storage component, and wherein the secondary energy from operations of the at least one crane component is recirculated energy, comprising in particular the following steps: activating at least one crane component in a working operation of the crane; Deactivating the at least one crane component in an idle mode of the crane; and control of the crane operation such that at intermittent operation, a ratio of the operating time to the idling operation time is at most 0.3, in particular comprising the step of providing the energy use portion to the at least one crane component by inducing an injection of energy into the power consumption system, in particular comprising the following steps: converting energy from the operation of the at least one crane component into power by means of at least one energy converter connected to the at least one crane component, and providing the energy share for the at least one crane component via the power from the at least one energy converter, in particular comprising the step the regulation of the energy supply of the at least one crane component by regulating a ratio of the proportion of energy use component to energy storage component, in particular comprising the step of calculating g of an energy surplus component such that a sum of the energy use component and the maximum energy storage component is equal to a sum of the energy surplus component and the total energy amount, in particular comprising the step of reducing the energy surplus component by converting energy from additional braking resistors into heat energy, wherein a return of the thermal energy to the crane Heating a crane cab is used.

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法律状态:
2019-08-15| MM01| Lapse because of not paying annual fees|Effective date: 20181231 |

优先权:

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申请号 | 申请日 | 专利标题

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US12/976,403|US8857635B2|2010-12-22|2010-12-22|Crane and method for operating a crane using recovery of energy from crane operations as a secondary energy source|

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