Manufacturing method of movable hanging basket special for flexible photovoltaic support

Abstract

The invention provides a manufacturing method of a movable hanging basket special for a flexible photovoltaic support, and belongs to the technical field of photovoltaic maintenance equipment. The manufacturing method of the movable hanging basket special for the flexible photovoltaic support comprises the steps of steel wire rope suspension system preparation, pulley assembly manufacturing, rectangular frame welding, bearing platform installation, enclosure system arrangement, connection system construction, movable control system installation, safety protection device arrangement and the like. Design and manufacturing of all parts are guided through mathematical models such as a hanging basket stability equation, a pulley assembly matching equation, a protection height calculation equation, a load distribution balance equation, a movement control force calculation equation, a shake suppression function and a multi-point stability balance function, and accurate matching of hanging basket structure parameters and operation requirements is achieved. The problems that a mobile operation hanging basket on an existing flexible photovoltaic support is insufficient in stability and low in safety can be solved.

Description

Technical Field

[0001] The present invention belongs to the technical field of photovoltaic maintenance equipment, and in particular relates to a method for manufacturing a mobile hanging basket dedicated to a flexible photovoltaic support. Background Art

[0002] The flexible construction of large-span photovoltaic power generation projects using "fish-solar complementary" technology requires installing triangular supports and photovoltaic panels on steel cables. Traditionally, this process involves fixed scaffolding or temporary work platforms, requiring repeated construction and dismantling, which is time-consuming, labor-intensive, and inefficient. For large-scale flexible photovoltaic support systems, simple hanging baskets can be used, moving along steel cables. However, these baskets are often temporary and lack a systematic design.

[0003] However, traditional mobile hanging baskets have many defects when used on flexible supports: the hanging basket has a simple structure, insufficient stability analysis, and is prone to shaking; the safety protection mechanism is imperfect, and there is a risk of falling; the mobile control system is rough, making it difficult to achieve precise positioning; the load distribution is uneven, which can easily cause the hanging basket to tilt; there is a lack of scientific parameter calculation methods, and the design relies more on experience rather than theoretical support.

[0004] These shortcomings lead to significant safety hazards and low efficiency when using traditional mobile baskets on flexible photovoltaic racks. In particular, when workers move within the basket or when wind speeds fluctuate, the basket can easily shake violently, disrupting normal operations and potentially endangering worker safety. Therefore, a method for fabricating a mobile basket for flexible photovoltaic racks based on theoretical calculations and structural optimization is urgently needed to address the core technical issues of insufficient stability and low safety in existing technologies. Summary of the Invention

[0005] In view of this, the present invention provides a method for manufacturing a mobile hanging basket dedicated to a flexible photovoltaic support, which can solve the technical problems in the prior art of insufficient stability and low safety of the mobile working hanging basket on the flexible photovoltaic support.

[0006] The present invention is achieved in that:

[0007] The present invention provides a method for manufacturing a mobile hanging basket specifically for a flexible photovoltaic support, which comprises the following steps: preparing a wire rope suspension system; manufacturing a hanging basket connecting and hanging part; manufacturing a hanging basket main structure; welding a load-bearing platform at the bottom of a hanging basket frame; installing a hanging basket enclosure system; connecting a pulley assembly and a hanging basket main body; installing a mobile control system; setting a safety protection device; performing an overall load test; applying a hanging basket stability equation to calculate a stability index of the hanging basket when running on a wire rope, and determining whether the stability of the hanging basket meets safety requirements according to a wire rope tension value, a hanging basket total weight, a hanging basket center of gravity position, a wire rope inclination angle, and a maximum offset distance of a worker; applying a pulley assembly matching equation to determine a clearance value between the pulley assembly and the wire rope; applying a protective height calculation equation to determine a minimum height value of a hanging basket enclosure system; applying a load distribution balance equation to calculate force values ​​at four connection points of the hanging basket; applying a mobile control force calculation equation to determine a minimum control force value required for moving the hanging basket; applying a sway suppression function to optimize the design of a safety protection device; and applying a multi-point stable balance function to optimize the design of a connection system.

[0008] On the basis of the above technical solution, the method for manufacturing a mobile hanging basket for a flexible photovoltaic support of the present invention can also be improved as follows:

[0009] Among them, the preparation of the wire rope suspension system specifically refers to fixing the steel wire rope with a diameter of 15.2 mm at the anchor points at both ends of the flexible photovoltaic bracket to ensure that the tension of the steel wire rope is appropriate and firmly fixed; the steel wire rope suspension system specifically refers to a support system composed of an anchoring device, prestressed steel wire rope and tensioning equipment, which is used to provide a walking track and support bearing capacity for the mobile hanging basket.

[0010] Furthermore, the production of the hanging basket connecting the suspension part specifically refers to the use of a high-strength pulley assembly, the inner diameter of the pulley is slightly larger than the diameter of the wire rope, and limit devices are set on both sides of the pulley assembly to prevent it from escaping from the wire rope; the high-strength pulley assembly specifically refers to a rolling bearing pulley that can withstand a load of not less than 3000 Newtons, the pulley groove type matches the wire rope diameter, and anti-slip groove guide devices are provided on both sides.

[0011] Furthermore, the production of the main structure of the hanging basket specifically refers to the use of 25mm square tubes to weld into a rectangular frame with a frame size of 150cm×100cm, and 45-degree diagonal braces are added at the four corners to enhance the overall rigidity; the main structure of the hanging basket specifically refers to a working platform frame welded from 25mm square tubes, including a main frame, reinforcing ribs, connecting nodes and guardrails, which constitute a platform for workers to stand and place materials; the welding of a bearing platform at the bottom of the hanging basket frame specifically refers to the use of anti-slip steel plates, and 10cm high anti-slip edges are welded around the platform to prevent tools from slipping; the installation of the hanging basket enclosure system specifically refers to the use of 120cm high standard steel grilles on all sides to ensure the safety of operators while maintaining a good field of vision; the connection of the pulley assembly with the hanging basket body specifically refers to setting connection points at the four corners of the top of the hanging basket, and reliably connecting the pulley assembly to the hanging basket through high-strength hooks.

[0012] Furthermore, the installation of a mobile control system specifically refers to setting up manual winch devices on both sides of the hanging basket, connecting the hanging basket with a fixed anchor point through a steel wire rope to enable the hanging basket to move along the direction of the steel cable; the mobile control system specifically refers to a device that retracts and releases the steel wire rope through a manual winch to move the hanging basket along the direction of the main steel wire rope, including a winch, an auxiliary steel wire rope, a guide pulley and a fixed anchor point; the setting of a safety protection device specifically refers to installing a safety pulley group independent of the main pulley system, equipped with an anti-fall locking mechanism, which automatically locks the steel wire rope when the main system fails; the anti-fall locking mechanism specifically refers to a mechanical device for automatically clamping the steel wire rope when the main pulley system fails or the moving speed exceeds the safety threshold, so as to prevent the hanging basket from falling suddenly.

[0013] Furthermore, the basket stability equation specifically refers to a mathematical relationship used to calculate the stability index of the basket when it is running on a wire rope. Its input includes the measured wire rope tension value, the determined total weight of the basket, the determined center of gravity position of the basket, the measured wire rope inclination angle, and the maximum offset distance of the staff determined according to the operation requirements. The output is the basket stability index, which is used to determine whether the basket design meets the safety and stability requirements.

[0014] Furthermore, the pulley assembly matching equation specifically refers to a mathematical relationship used to determine the optimal matching relationship between the pulley assembly and the wire rope. Its input includes the measured wire rope diameter, the determined expected maximum load, the determined pulley inner diameter, the elastic modulus provided by the pulley material specification, and the friction coefficient provided by the pulley bearing specification. The output is the gap value between the pulley assembly and the wire rope, which is used to guide the selection and processing of the pulley assembly.

[0015] Furthermore, the protection height calculation equation specifically refers to a mathematical relationship used to determine the minimum height of the hanging basket enclosure system. Its input includes the average height of operators provided by the operator height statistics, the calculated maximum swing amplitude of the hanging basket, the working posture height coefficient determined by the working requirements, the safety redundancy height required by the safety regulations, and the maximum height of the working tool determined by the working tool specifications. The output is the minimum height value of the enclosure system, which is used to guide the design and installation of the enclosure system.

[0016] Furthermore, the load distribution balance equation specifically refers to a mathematical relationship used to calculate the force distribution at the four connection points of the hanging basket. Its input includes the determined deadweight of the hanging basket, the weight of the staff specified in the operation requirements, the weight of the working materials determined by the operation material list, the wind load parameters provided by the meteorological data, and the determined size parameters of the hanging basket. The output is the force values ​​of the four connection points, which are used to guide the design and layout of the connection points.

[0017] Furthermore, the movement control force calculation equation specifically refers to a mathematical relationship used to determine the minimum control force required to move the basket. Its input includes the determined total weight of the basket, the measured wire rope tension, the friction coefficient between the wire rope and the pulley provided in the material specification, the measured wire rope inclination, and the determined basket motion damping coefficient. The output is the minimum control force value required to move the basket, which is used to guide the selection and design of the manual winch.

[0018] This invention provides a method for fabricating a mobile basket for a flexible photovoltaic support. Through a systematic design process and theoretical calculations, the method achieves high stability and safety for the mobile basket. This method utilizes multiple specialized mathematical models, including a basket stability equation, a pulley assembly matching equation, and a protective height calculation equation, to guide the precise design and fabrication of the basket's components, ensuring that the basket's structural parameters are precisely matched to operational requirements.

[0019] The present invention solves the main defects of traditional mobile hanging baskets: by optimizing the connection system design through multi-point stable balance function, the stability of the hanging basket under various load conditions is significantly improved; an independent anti-fall locking mechanism and safety pulley set are adopted to form a dual safety guarantee system, greatly improving safety and reliability; a damping device designed with a sway suppression function is used to effectively reduce the sway amplitude during operation; the load distribution balance equation ensures that the four connection points are subjected to balanced forces to prevent the hanging basket from tilting; the manual winch control system cooperates with the precisely calculated control force to achieve smooth and precise movement control.

[0020] Based on scientific calculations and engineering mechanics principles, the present invention systematically solves the technical problems of insufficient stability and low safety of the mobile work basket on the flexible photovoltaic bracket, enabling workers to safely and efficiently complete the installation, maintenance and inspection of the flexible photovoltaic bracket in a high-altitude environment, providing reliable technical support for the full life cycle management of the flexible photovoltaic bracket system. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 This is a flow chart of a method for making a mobile hanging basket specifically for a flexible photovoltaic support;

[0022] Figure 2 This is a front view of a mobile hanging basket dedicated to a flexible photovoltaic support;

[0023] Figure 3 This is a side view of a mobile hanging basket dedicated to a flexible photovoltaic support;

[0024] Figure 4 This is a schematic diagram of an anti-slip groove guide device for a mobile hanging basket dedicated to a flexible photovoltaic support;

[0025] In the accompanying drawings, the components represented by the reference numerals are as follows:

[0026] 10. Main structure of hanging basket; 11. Main frame; 12. Reinforcement ribs; 13. Guardrails; 14. Loading platform; 20. Steel wire rope; 30. Manual winch; 31. Winch; 32. Auxiliary steel wire; 33. Guide pulley; 40. Safety protection device; 50. Anti-slip groove guide device. DETAILED DESCRIPTION

[0027] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0028] like Figure 1 FIG. 1 is a flow chart of a method for manufacturing a mobile hanging basket for a flexible photovoltaic support provided by the present invention. The method comprises the following steps:

[0029] S01. Prepare the wire rope suspension system and fix the 15.2mm diameter wire rope to the anchor points at both ends of the flexible photovoltaic support, ensuring that the wire rope tension is appropriate and securely fixed;

[0030] S02. Make the hanging basket connecting the suspension part, using a high-strength pulley assembly with an inner diameter slightly larger than the diameter of the wire rope. Set limit devices on both sides of the pulley assembly to prevent it from escaping from the wire rope;

[0031] S03. Make the main structure 10 of the hanging basket by welding 25mm square tubes into a rectangular frame with a frame size of 150cm×100cm. Add 45-degree diagonal braces at the four corners to enhance the overall rigidity.

[0032] S04. Weld a load-bearing platform 14 at the bottom of the hanging basket frame. Make it with anti-skid steel plates. Weld 10cm high anti-skid edges around the platform to prevent tools from slipping.

[0033] S05. Install the hanging basket enclosure system, using 120cm high standard steel grilles around to ensure the safety of operators while maintaining a good field of vision;

[0034] S06. Connect the pulley assembly to the main body of the hanging basket, set connection points at the four corners of the top of the hanging basket, and reliably connect the pulley assembly to the hanging basket through high-strength hooks;

[0035] S07, install the mobile control system, set up manual winches 30 on both sides of the hanging basket, and connect the hanging basket to the fixed anchor point through the wire rope 20 to achieve the movement of the hanging basket along the wire rope direction;

[0036] S08. Setting a safety protection device 40, installing a safety pulley block independent of the main pulley system, and equipping it with an anti-fall locking mechanism to automatically lock the wire rope when the main system fails;

[0037] S09. Conduct an overall load test, perform a static load test at 1.5 times the design load, and perform a dynamic test under actual working conditions to ensure that the basket moves smoothly, safely and reliably;

[0038] S10. Use the basket stability equation to calculate the stability index of the basket when it is running on the wire rope. Based on the wire rope tension value, the total weight of the basket, the position of the basket's center of gravity, the inclination angle of the wire rope, and the maximum deviation distance of the workers, determine whether the basket stability meets the safety requirement of greater than 1.5;

[0039] S11. Use the pulley assembly matching equation to determine the clearance between the pulley assembly and the wire rope. Based on the wire rope diameter, expected maximum load, pulley inner diameter, pulley material elastic modulus, and pulley bearing friction coefficient, calculate that the clearance between the pulley assembly and the wire rope is maintained between 0.5 mm and 1.5 mm.

[0040] S12. Use the protective height calculation equation to determine the minimum height of the hanging basket enclosure system. Calculate the required minimum height of the enclosure system based on the average height of the operator, the maximum swing amplitude of the hanging basket, the height coefficient of the working posture, the safety margin height, and the maximum height of the working tool.

[0041] S13. Apply the load distribution balance equation to calculate the forces at the four connection points of the hanging basket. Ensure that the forces at the four connection points are balanced based on the weight of the hanging basket, the weight of the workers, the weight of the work materials, the wind load, and the size parameters of the hanging basket to prevent the hanging basket from tilting or shaking.

[0042] S14. Determine the minimum control force required to move the basket using the movement control force calculation equation. Calculate the control force required by the manual winch 30 based on the basket's total weight, the wire rope tension, the friction coefficient between the wire rope and the pulley, the wire rope inclination, and the basket's motion damping coefficient.

[0043] S15. Apply the sway suppression function to optimize the design of the safety protection device. Based on the wire rope tension value, the total weight of the hanging basket, the wind speed parameters, the operator's movement frequency, and the damping coefficient parameters, calculate the optimal damping device parameter configuration, and install the corresponding damper to reduce the sway amplitude of the hanging basket during use;

[0044] S16. Apply the multi-point stability balance function to optimize the connection system design. Determine the optimal connection point layout based on the center of gravity position of the basket, the expected maximum load distribution, the wire rope pre-tension value, the dynamic coefficient of the working posture, and the environmental wind load coefficient to improve the stability of the basket under various load conditions.

[0045] like Figure 2-4 As shown, the wire rope suspension system specifically refers to a support system composed of an anchoring device, prestressed wire ropes and tensioning equipment, which is used to provide a walking track and support bearing capacity for the mobile hanging basket.

[0046] Among them, the main structure of the hanging basket specifically refers to the working platform frame welded from 25mm square tubes, including the main frame 11, reinforcement ribs 12, connection nodes and guardrails 13, which constitute the platform for workers to stand and place materials.

[0047] The high-strength pulley assembly specifically refers to a rolling bearing pulley capable of withstanding a load of no less than 3,000 Newtons. The pulley groove matches the diameter of the wire rope, and anti-slip groove guide devices 50 are provided on both sides.

[0048] Among them, the anti-fall locking mechanism specifically refers to a mechanical device that can automatically clamp the wire rope when the main pulley system fails or the moving speed exceeds the safety threshold to prevent the hanging basket from falling suddenly.

[0049] Among them, the mobile control system specifically refers to a device that uses a manual winch to retract and release the wire rope to move the hanging basket along the direction of the main wire rope, including a winch 31, an auxiliary wire rope 32, a guide pulley 33 and a fixed anchor point.

[0050] Among them, the basket stability equation specifically refers to a mathematical relationship used to calculate the stability index of the basket when it runs on the wire rope. Its input includes the wire rope tension value measured in step S01, the total weight of the basket determined in steps S03 to S05, the center of gravity position of the basket determined in step S03, the wire rope inclination measured in step S01, and the maximum offset distance of the staff determined according to the operation requirements. The output is the basket stability index, which is used to determine whether the basket design meets the safety and stability requirements.

[0051] Among them, the pulley assembly matching equation specifically refers to a mathematical relationship used to determine the optimal matching relationship between the pulley assembly and the wire rope. Its input includes the wire rope diameter measured in step S01, the expected maximum load determined in step S09, the pulley inner diameter determined in step S02, the elastic modulus provided in the pulley material specification, and the friction coefficient provided in the pulley bearing specification. The output is the gap value between the pulley assembly and the wire rope, which is used to guide the selection and processing of the pulley assembly in step S02.

[0052] Among them, the protection height calculation equation specifically refers to a mathematical relationship used to determine the minimum height of the hanging basket enclosure system. Its input includes the average height of operators provided by the operator height statistics, the maximum swing amplitude of the hanging basket calculated in step S10, the working posture height coefficient determined by the working requirements, the safety redundancy height required by the safety regulations, and the maximum height of the working tool determined by the working tool specifications. The output is the minimum height value of the enclosure system, which is used to guide the design and installation of the enclosure system in step S05.

[0053] Among them, the load distribution balance equation specifically refers to the mathematical relationship used to calculate the force distribution of the four connection points of the hanging basket. Its input includes the dead weight of the hanging basket determined in steps S03 to S05, the weight of the staff specified in the operation requirements, the weight of the working materials determined in the work material list, the wind load parameters provided by the meteorological data, and the size parameters of the hanging basket determined in step S03. The output is the force values ​​of the four connection points, which are used to guide the design and arrangement of the connection points in step S06.

[0054] Among them, the movement control force calculation equation specifically refers to the mathematical relationship used to determine the minimum control force required to move the hanging basket. Its input includes the total weight of the hanging basket determined in steps S03 to S05, the wire rope tension measured in step S01, the friction coefficient between the wire rope and the pulley provided in the material specification, the wire rope inclination measured in step S01, and the hanging basket motion damping coefficient determined in step S15. The output is the minimum control force value required to move the hanging basket, which is used to guide the selection and design of the manual winch in step S07.

[0055] The sway suppression function specifically refers to an algorithmic program used to optimize the design of safety protection devices. Its input includes the wire rope tension value measured in step S01, the total weight of the hanging basket determined in steps S03 to S05, the wind speed parameters provided by meteorological data, the operator movement frequency determined by the operation requirements, and the damping coefficient parameters provided by the material specification. The output is the optimal damping device parameter configuration, which is used to guide the selection and installation of the damping device in step S08.

[0056] Among them, the multi-point stable balance function specifically refers to an algorithm program used to optimize the design of the connection system. Its input includes the center of gravity position of the basket determined in step S03, the expected maximum load distribution calculated in step S13, the wire rope pretension value measured in step S01, the dynamic coefficient of the working posture determined by the working requirements, and the environmental wind load coefficient provided by the meteorological data. The output is the optimal connection point layout plan, which is used to guide the optimized design of the connection system in step S06.

[0057] Among them, the working posture height coefficient specifically refers to the ratio of the highest point of the operator's body to the standing height under different working postures, which is determined through ergonomic measurements.

[0058] Among them, the dynamic coefficient of the working posture specifically refers to the quantitative parameter of the influence of the operator on the balance of the hanging basket under different working postures, which is determined through dynamic analysis and experimental measurement.

[0059] Among them, the maximum swing amplitude of the hanging basket specifically refers to the maximum swing distance that the hanging basket may have under various working conditions, which is determined through dynamic analysis and actual testing.

[0060] Among them, the environmental wind load coefficient specifically refers to the quantitative parameter of the impact of wind force on the stability of the hanging basket under different wind speed conditions, which is determined through wind tunnel tests and meteorological data analysis.

[0061] Among them, the basket motion damping coefficient specifically refers to the damping characteristic parameters when the basket moves on the wire rope, which is determined by the material properties and structural design and obtained through actual testing.

[0062] The specific implementation of the above steps is described in detail below.

[0063] The specific implementation method of step S01 is to preset anchor point positions at both ends of the flexible photovoltaic bracket, and use professional drilling equipment to drill anchor holes with a diameter of 20mm and a depth of not less than 200mm. A high-strength, low-relaxation steel wire rope with a diameter of 15.2mm is selected, and the tensile strength of the steel wire rope is not less than 1860 MPa. After one end of the steel wire rope is passed through the anchor hole, it is fixed with no less than 3 steel wire rope clamps. The other end is prestressed by hydraulic tensioning equipment, and the tensioning force value is controlled within the range of 40% to 60% of the ultimate bearing capacity of the steel wire rope, that is, between 22 and 33kN. After the tensioning is completed, it is also fixed with no less than 3 steel wire rope clamps, and the steel wire rope clamp bolts are tightened with a torque wrench to a torque value of 150 Nm. After the tensioning is completed, the tension of the steel wire rope is tested using a tensiometer to ensure that the tension value is stable within the range of ±5% of the design value. The purpose of this step is to establish a stable and reliable suspension system to provide a safe operating track for the subsequent hanging basket.

[0064] The specific implementation of step S02 is based on the principles of tribology and material mechanics. The pulley body is constructed from bearing steel, and the pulley groove adopts a U-shaped design with a groove depth of no less than 1.3 times the diameter of the wire rope. The pulley has an inner diameter of 16.5 mm, creating a 1.3 mm gap with the 15.2 mm wire rope. This gap value is calculated using the pulley assembly matching equation to ensure that the pulley will not deform and jam the wire rope under load, while also preventing wobble due to excessive gap. The pulley is supported by double-row angular contact ball bearings with a dynamic load capacity of no less than 5000 Newtons. Anti-slip guides are installed on both sides of the pulley. The guides maintain a 0.5 mm to 1 mm gap with the wire rope, preventing the wire rope from escaping the pulley groove when the pulley tilts. The anti-slip guides are made of polytetrafluoroethylene to reduce the friction coefficient when in contact with the wire rope. Each hanging basket is equipped with four main pulley sets and two safety pulley sets. The main pulley sets use a double pulley design to increase the contact area and reduce the pressure per unit area. The purpose of this step is to ensure that the basket can move smoothly on the wire rope and prevent it from being separated from the wire rope due to pulley failure.

[0065] The specific implementation method of step S03 is to use 25mm square tubes made of Q345 steel with a wall thickness of not less than 2mm, and arrange the frame according to the size of 150cm×100cm. The main body of the frame is connected by welding, and the welds are continuous welding, and the weld height is not less than the wall thickness. The four corners of the frame are reinforced with 45-degree diagonal braces, the length of the diagonal braces is 50cm, and they are also made of 25mm square tubes. A transverse reinforcement rib is added every 50cm along the length of the middle part of the frame, and the reinforcement rib is connected to the main frame by full welding. Each connection node of the frame is reinforced with thickened steel plates with a thickness of 8mm and an area of ​​not less than 10cm×10cm. According to the finite element analysis of structural mechanics, the maximum deflection of the frame structure under the condition of a uniformly distributed load of 300kg does not exceed 1 / 200 of the frame length, which meets the stiffness requirements. Pulley assembly connection points are reserved at each corner of the frame. The connection points are made of 12mm thick high-strength steel plates and are firmly connected to the main frame by double-sided welding. The purpose of this step is to build the main structure that carries personnel and materials, ensuring that the overall strength and rigidity meet the requirements of use.

[0066] The specific implementation of step S04 involves welding a 4mm thick patterned steel plate to the bottom of the frame produced in step S03. The surface of the steel plate features a diamond-shaped anti-slip pattern with a friction coefficient of no less than 0.6. Reinforcing ribs are placed every 20cm between the steel plate and the frame, made from 10mm x 20mm flat steel. The steel plate is bent upward on all sides to form a 10cm high anti-slip edge, with a bend radius of 5mm to prevent cracking at the bend. The corners of the anti-slip edge are reinforced with angle steel to prevent deformation due to collisions. Multiple drainage holes with a diameter of 10mm, spaced no more than 30cm apart, are provided on the platform surface to prevent rainwater accumulation. Four tool attachment points are reserved on the platform, connected using M10 bolts, for convenient securing of commonly used tools. The load-bearing platform is designed to withstand a 200kg uniformly distributed load plus a 50kg concentrated load. Static analysis ensures that the platform will not permanently deform under the most adverse loading conditions. The purpose of this step is to provide a safe and stable working platform to prevent tools and materials from slipping, while also ensuring the platform has sufficient load-bearing capacity.

[0067] The specific implementation of step S05 involves constructing a protective frame using 25mm×25mm×3mm angle steel. The height of the frame is 120cm, determined according to a protective height calculation equation. This equation takes into account parameters such as an average worker height of 175cm, a working posture height coefficient of 1.15 (the highest working posture is hunched over and head-up), a maximum swing amplitude of 10cm for the hanging basket, a safety margin height of 15cm, and a maximum height of 30cm for working tools. The spacing between the columns of the protective frame is no more than 50cm, and a horizontal fence is installed at the top and center. The protective system utilizes standard welded steel grating with a mesh size of 50mm×100mm. The grating is connected to the frame using M8 bolts with a spacing of no more than 30cm. A 60cm-wide entrance is provided on one side of the protective system, with a double security door design. The outer door uses a conventional hinged door design, and the inner door uses an inward-opening spring door design, ensuring that at least one door is always closed. Conspicuous yellow and black warning signs are painted on the four corners and entrance of the protective system. The purpose of this step is to ensure the personal safety of operators when working at height, while maintaining a good working field of vision and improving working efficiency.

[0068] The specific implementation method of step S06 is to determine the position and stress of the four connection points based on the load distribution balance equation. The input parameters of this equation include the weight of the hanging basket 160kg, the weight of the staff 150kg (considering two people working at the same time), the weight of the working material 100kg, the wind load calculated according to the 8-level wind speed of 102.7 Newtons, and the size of the hanging basket 150cm×100cm. The calculation results show that the ideal position of the four connection points should be 10cm inside the four corners of the frame. The stress at this position is the most balanced, and the stress difference at the four points does not exceed 5%. High-strength lifting rings are installed at the connection points. The lifting ring material is 40Cr alloy steel, and the heat treatment hardness reaches HRC40 or above. The safe working load of a single lifting ring is not less than 500kg. The lifting ring and the frame are connected with M16 high-strength bolts, and the bolt tightening torque is 180 Newton meters. A high-strength hook is connected to the lifting ring. The hook is made of forging technology and the surface is galvanized for corrosion protection. The hook has a safety locking device to prevent the pulley assembly from accidentally falling off during use. The connection system design follows the results of a multi-point stability balance function optimization, taking into account the basket's center of gravity, the expected maximum load distribution, a wire rope pretension of 25kN, a dynamic coefficient of 1.3 for the operating posture, and an ambient wind load coefficient of 1.8. This step ensures a reliable and secure connection between the pulley assembly and the basket body, evenly distributing the load and minimizing basket tilt and sway.

[0069] The specific implementation of step S07 involves installing manual winches on both sides of the basket. The winches have a maximum load capacity of no less than 500 kg and utilize a worm gear transmission with a transmission ratio of 1:30, ensuring ease of operation and a self-locking function. The winches are mounted on a bracket, which is connected to the main frame of the basket using M12 bolts. An auxiliary steel wire rope with an 8 mm diameter is wound around the winch. One end of the rope is secured to the winch drum, and the other end is returned to the vicinity of the basket via a fixed ground anchor point. The fixed anchor points are located 1.5 times the width of the basket from the main anchor points at both ends, ensuring a sufficient angle between the auxiliary rope and the main rope to maximize the control force vector component. Based on the equation for calculating the control force for movement, considering the basket's total weight of 410 kg, a wire rope tension of 25 kN, a friction coefficient of 0.15 between the rope and the pulley, a wire rope inclination of 5 degrees, and a basket motion damping coefficient of 0.25, the minimum control force required to move the basket is calculated to be 150 Newtons. The winch handle is 40 cm long, and the force required for single-person operation does not exceed 50 Newtons, meeting ergonomic requirements. A ratchet locking mechanism ensures the basket's position remains unchanged when the handle is released. This provides reliable movement control, allowing the operator to easily control the basket's movement along the wire rope and securely dock it at any position.

[0070] The specific implementation of step S08 involves installing a safety protection device independent of the main pulley system, including a safety pulley block and an anti-fall locking mechanism. The safety pulley block utilizes pulleys of the same specifications as the main pulley block, but with different connection methods and locations to prevent the same fault from affecting both systems simultaneously. The anti-fall locking mechanism utilizes a centrifugal braking principle, automatically triggering the lock when the moving speed exceeds the safety threshold of 0.5 m / s. The locking mechanism is cast from a high-strength aluminum alloy, reducing weight while ensuring strength. A specially shaped brake pad is installed within the locking mechanism, made of wear-resistant alloy steel with a hardness exceeding HRC 55. The brake pad is preloaded by a compression spring with an initial spring pressure of 300 N. When the lock is triggered, the brake pad contacts the wire rope, generating a friction torque exceeding 1000 N·m, capable of fully braking the basket within 0.2 seconds. The locking mechanism is equipped with a manual reset device to ensure rapid recovery in the event of an accidental triggering. The safety system also features an overload alarm that emits an audible and visual alarm when the load exceeds 85% of the design load. The purpose of this step is to build a multi-layer safety assurance system to prevent safety accidents caused by equipment failure or operational errors and to protect the lives of operators.

[0071] Step S09 involves conducting a load test on the basket in accordance with international safety standards. The static load test is conducted at 1.5 times the design load, or 615 kg, for at least one hour. The basket components are observed for deformation or damage. The static load test uses standard weights or water bags evenly distributed on the load platform. The dynamic test consists of two parts: the first is a test of the basket's mobility. The basket is loaded with 100% of the design load, or 410 kg, and moves back and forth three times on the wire rope, each time a distance of at least 10 meters. The resistance changes and sway amplitude during movement are recorded. The second is a test of the safety device, simulating failure scenarios under different load conditions to verify whether the safety device can function effectively and promptly. During the test, all key parameters, such as movement speed, docking stability, and braking distance, are recorded and compared to design requirements. This test confirms that the basket's functions meet design requirements, particularly that the basket moves smoothly when fully loaded, brakes reliably, and that the safety device responds quickly. The purpose of this step is to verify the reliability of the basket's design and construction through actual load testing, ensuring safe and reliable operation under actual operating conditions.

[0072] The specific implementation of step S10 involves applying the basket stability equation to calculate the stability index of the basket while it is operating on the wire rope. This equation, based on the principle of mechanical equilibrium, accounts for multiple forces, including gravity, wind, and dynamic loads. Input parameters include a wire rope tension of 25 kN, a total basket weight of 410 kg, the basket's center of gravity (horizontally offset by 5 cm and vertically offset by -20 cm from the geometric center), a wire rope inclination of 5 degrees, and a maximum worker offset distance of 60 cm. The calculation utilizes a numerical integration method, taking into account nonlinear factors such as the pulsating effects of wind loads and the impact coefficient of personnel movement. The stability index is defined as the ratio of the minimum anti-overturning moment to the maximum overturning moment, and safety standards require this value to be greater than 1.5. Calculation results show that under the most unfavorable operating conditions (a fully loaded basket, two workers simultaneously positioned on one side, and a force 8 crosswind), the stability index is 1.78, meeting safety requirements. Parameter sensitivity analysis revealed that worker position distribution has the greatest impact on stability. Therefore, in actual operating procedures, workers are required to avoid being simultaneously positioned on the same side of the basket. The purpose of this step is to verify the stability of the hanging basket design through theoretical calculations to ensure that it will not capsize under various working conditions.

[0073] The specific implementation of step S11 involves applying the pulley assembly matching equation to determine the optimal clearance between the pulley assembly and the wire rope. This equation, based on contact mechanics theory, takes into account factors such as material elastic deformation and frictional thermal expansion. Input parameters include a wire rope diameter of 15.2 mm, an expected maximum load of 615 kg (1.5 times the design load), an initial pulley inner diameter, a pulley material elastic modulus of 210 GPa (bearing steel), and a pulley bearing friction coefficient of 0.05. The equation uses iterative calculations to analyze the relationship between the pulley's operating resistance and service life for different clearance values, ultimately determining an optimal clearance of 1.3 mm. This value ensures that the pulley will not jam the wire rope due to elastic deformation of the material under full load, while also ensuring that the clearance is not excessive enough to increase vibration. Based on this result, the pulley inner diameter is determined to be 16.5 mm. Furthermore, to account for the effects of temperature on the material, the equation also calculates the effects of thermal expansion within an ambient temperature range of -20°C to 50°C, confirming that the clearance between the pulley and the wire rope remains between 0.5 mm and 1.5 mm within this temperature range, meeting safe operation requirements. The purpose of this step is to determine the optimal matching relationship between the pulley and the wire rope through precise calculation to ensure that the hanging basket moves smoothly.

[0074] The specific implementation of step S12 is to apply the protective height calculation equation to determine the minimum height of the hanging basket enclosure system. This equation is based on ergonomic principles and comprehensively considers operator safety and operational convenience. Input parameters include an average operator height of 175 cm (according to the Chinese adult male height standard), a maximum hanging basket sway amplitude of 10 cm (determined by dynamic testing), a working posture height coefficient of 1.15 (accounting for working postures such as bending over and raising the head), a safety margin height of 15 cm, and a maximum working tool height of 30 cm (based on common tool sizes). The calculation uses a linear combination method, taking into account the weight coefficients of each parameter. The calculation results show that the minimum height of the enclosure system should be 118.75 cm, rounded to 120 cm. This height ensures that the operator is effectively protected in various working postures, while not being too high to affect the operator's vision and work efficiency. The actual design uses a modular enclosure system, which can be adjusted according to the specific working conditions. The basic height is 120 cm, which can be increased to 150 cm for special conditions. The purpose of this step is to determine the optimal height of the enclosure system to ensure operator safety without affecting work efficiency.

[0075] The specific implementation method of step S13 is to apply the load distribution balance equation to calculate the force values ​​of the four connection points of the hanging basket to ensure that the force at each connection point is balanced. The equation is based on the principle of static equilibrium and the finite element analysis method. The input parameters include the weight of the hanging basket of 160kg, the weight of the staff of 150kg (considering 2 people working at the same time), the weight of the working material of 100kg, the wind load calculated as 102.7 Newtons according to the wind speed of level 8, and the size of the hanging basket of 150cm×100cm. The equation takes into account the factors of center of gravity offset and dynamic load, and adopts the rigid body dynamics model for analysis. The calculation results show that under the most unfavorable working conditions (two staff members are in one corner at the same time, and the materials are stacked on the same side), the maximum force difference of the four connection points is 29.3%, which exceeds the design target by 20%. By adjusting the position of the connection point (moving 5cm to the heavy-load side) and the arrangement of the reinforcement, the optimized force difference is reduced to 18.7%, meeting the design requirements. The final four connection points were located 10 cm from the inside of the frame corners. Each connection point was designed to bear a load of 500 kg, but the actual maximum load was 320 kg, resulting in a safety factor of 1.56. This step aims to ensure the basket's suspension balance through precise calculations, preventing excessive tilt or sway due to uneven load distribution.

[0076] The specific implementation of step S14 involves applying a motion control force calculation equation to determine the minimum control force required to move the basket, providing a basis for manual winch design. This equation, based on mechanical transmission principles and friction mechanics, takes into account factors such as static friction, rolling friction, and the system's deadweight. Input parameters include a basket total weight of 410 kg, a wire rope tension of 25 kN, a friction coefficient of 0.15 between the wire rope and the pulley, a wire rope inclination of 5 degrees, and a basket motion damping coefficient of 0.25. The equation uses vector decomposition to calculate the force components in each direction, taking into account the difference between the starting force and the sustained motion force. The calculation results show that the minimum control force required to start the basket when stationary is 172 Newtons, and the control force required to maintain motion when in motion is 138 Newtons. The larger value of 172 Newtons is used as the design value. Based on this control force, the winch transmission ratio is designed to be 1:30, the handle length is 40 cm, and the force applied by a single operator at the handle end is approximately 46 Newtons, meeting ergonomic standards (single-person sustained operating force does not exceed 50 Newtons). The winch drum has a diameter of 150mm, and the basket moves approximately 16cm per rotation, making it easy to precisely control the position. This step ensures that the basket movement control system is well designed and easy to operate.

[0077] The specific implementation of step S15 involves applying a sway suppression function to optimize the design of the safety protection device to reduce the sway amplitude of the basket during use. This function is based on vibration dynamics theory and damping control principles. Its input parameters include a wire rope tension of 25 kN, a total basket weight of 410 kg, wind speed parameters (considering force 6 winds of 20.8-24.4 m / s), operator movement frequency (on average, one large movement every 30 seconds), and a damping coefficient parameter (initial value 0.15). The function uses a multivariable optimization algorithm to analyze the impact of different damping device parameters on the system's vibration response and identify the optimal damping configuration. Calculation results show that the optimal damping coefficient is 0.25, which reduces the maximum sway amplitude of the basket from 18.6 cm in the unoptimized state to 10.2 cm. Based on these calculations, two sets of hydraulic dampers were installed, located diagonally on the basket. The damping force varies nonlinearly with displacement velocity, with low damping force at low speeds (allowing the operator to move without noticeable resistance) and high damping force at high speeds (effectively suppressing sudden sway). The damper uses a temperature compensation design to ensure stable performance within the temperature range of -20°C to 50°C. The purpose of this step is to optimize the damping device design through scientific calculations to improve the stability and operating comfort of the hanging basket.

[0078] Step S16 specifically involves applying a multi-point stability balance function to optimize the connection system design, improving the stability of the gantry under various load conditions. This function, based on multibody dynamics theory and topology optimization methods, takes as input the position of the gantry's center of gravity (horizontally offset by 5 cm and vertically offset by -20 cm from the geometric center), the expected maximum load distribution (based on the calculation results of step S13), a wire rope pretension of 25 kN, a dynamic coefficient of 1.3 for the working posture, and an ambient wind load coefficient of 1.8. The function establishes a coupled dynamic model of the gantry, connection system, and wire ropes to simulate and analyze the system's stability under different connection point layouts. The optimization objective is to minimize the maximum sway amplitude under various operating conditions. Calculation results show that compared to the initial design (connection points located at the four corners of the frame), the optimized connection point layout (offset inward by 10 cm and adjusted 5 cm toward the center of gravity) reduces the maximum sway amplitude by 23.5%. Furthermore, the optimization includes adding damping components to the connection system and using composite shock-absorbing pads to reduce impact load transmission. The final connection system design utilizes adjusted connection point locations, high-strength connectors, and shock-absorbing devices to maximize stability while ensuring load-bearing capacity. The goal of this step is to optimize the connection system design to improve overall structural stability, reduce shaking, and enhance safety and comfort.

[0079] The detailed structure of the mobile hanging basket of the flexible photovoltaic support consists of the following main parts: one is the wire rope suspension system, including a high-strength steel wire rope with a diameter of 15.2mm, an anchoring device and a tensioning device to form a track for the movement of the hanging basket; the second is the pulley connection suspension part, including a high-strength pulley assembly with an inner diameter of 16.5mm, an anti-slip guide device and a connecting hook to realize the connection between the hanging basket and the wire rope; the third is the main structure of the hanging basket, a 150cm×100cm rectangular frame welded from 25mm square tubes, equipped with 45-degree diagonal braces and transverse reinforcement ribs; the fourth is the load-bearing platform, made of 4mm thick patterned steel plate, with 10cm high anti-slip edges on all sides; the fifth is the enclosure system, a 120cm high steel grille fence equipped with a safety door; the sixth is the mobile control system, including manual winches on both sides, 8mm auxiliary steel wire ropes and fixed anchor points; the seventh is the safety protection device, including a safety pulley set, an anti-fall locking mechanism and a hydraulic damper. The entire system has a designed load capacity of 410kg, a maximum mobile control force of 172N, and a stability index of 1.78, meeting safety requirements.

[0080] The mathematical model or calculation process involved in the present invention is described in detail below.

[0081] The basket stability equation is used to calculate the stability index of the basket when it is running on the wire rope, which is expressed as follows:

[0082]

[0083] Where SI is the stability index, dimensionless, and the safety requirement is greater than 1.5; M resist is the minimum anti-overturning moment, in Nm; M overturn is the maximum overturning moment, in N·m.

[0084] Further expansion yields:

[0085]

[0086] Where, T is the wire rope tension value, the unit is Newton, and the measured value is 25000 Newton; d vert is the vertical moment arm, in meters, which is the vertical distance from the pulley block to the center of gravity of the basket; α is the angle between the wire rope and the horizontal plane, in degrees, and the measured value is 5 degrees; W is the total weight of the basket, in Newtons, which is 410 kg multiplied by the acceleration of gravity; d horiz is the horizontal moment arm, in meters, which is the horizontal distance from the center of gravity of the basket to the edge of overturning; β is the tilt angle of the basket, in degrees, which is close to 0 degrees under normal working conditions; F wind is the wind load, in Newton, calculated as 102.7 Newton at level 8 wind speed; h center W is the height of wind load, in meters, which is the height of the center of gravity of the hanging basket; person is the weight of the worker, in units of oxen, and is 75 kg / person multiplied by the acceleration due to gravity; d max is the maximum offset distance of the staff, in meters, with a value of 0.6 meters; γ dyn is the dynamic load factor, dimensionless, and its value is 1.3.

[0087] Taking into account the pulsation effect of wind load, the pulsation coefficient is introduced:

[0088] F wind =ρ·A·v 2 ·Cd · (1+ξ·sin(2πft));

[0089] Where ρ is the air density in kilograms per cubic meter, with a standard value of 1.29; A is the windward area in square meters, calculated based on the size of the hanging basket; v is the wind speed in meters per second, with a value range of 17.2-20.7 meters per second for level 8 wind; C d is the drag coefficient, dimensionless, with a value of 1.2; ξ is the pulsation intensity coefficient, dimensionless, with a value range of 0.2-0.3; f is the pulsation frequency, in Hertz, with a value range of 0.1-0.5 Hertz; t is the time variable, in seconds.

[0090] The parameter acquisition method is:

[0091] T uses a tensiometer to directly measure the tension of the wire rope; α uses an inclinometer to measure the angle between the wire rope and the horizontal plane; W obtains the weight of each component of the hanging basket by weighing and summing them; F wind Calculated based on meteorological data and the windward area of ​​the hanging basket; d vert and d horiz Obtained by actually measuring the geometric dimensions of the hanging basket; β is measured using an inclinometer under actual working conditions; γ dyn It is determined through dynamic load testing, which simulates the rapid movement of workers on the hanging basket and records the ratio of the peak load to the static load.

[0092] The basket stability equation is based on the principle of moment balance. It takes into account various factors that the basket may face in actual working conditions. By calculating the ratio of the anti-overturning moment to the overturning moment, it is determined whether the basket stability meets the safety requirements. This equation comprehensively considers static factors (such as the basket's own weight and center of gravity position) and dynamic factors (such as wind load and personnel movement), and can comprehensively evaluate the stability of the basket. The power relationship (such as the squared wind speed term in the wind load calculation) reflects the laws of physics, and the cosine function of the inclination angle reflects the components of the force in different directions. The innovation of this equation lies in the introduction of pulsation effects and dynamic load coefficients, which are closer to actual working conditions.

[0093] The pulley assembly matching equation is used to determine the optimal gap value between the pulley assembly and the wire rope, which is specifically expressed as follows:

[0094] G=D pulley -D rope -2ΔD deform -ΔD thermal ;

[0095] Where G is the gap between the pulley and the wire rope, in mm, with an optimal range of 0.5-1.5 mm; D pulley is the inner diameter of the pulley, in mm, and the initial design value is 16.5 mm; D rope is the wire rope diameter, in mm, the standard value is 15.2mm; ΔD deform is the deformation of the pulley under load, in mm; ΔD thermal It is the dimensional change caused by temperature change, in mm.

[0096] Calculation of pulley deformation:

[0097]

[0098] Where, F load is the expected maximum load, in Newtons, and is 615 kg multiplied by the acceleration due to gravity; R pulley is the pulley radius, in mm, which is half of the inner diameter; E pulleyis the elastic modulus of the pulley material, in GPa, and the value for bearing steel is 210 GPa; μ pulley k is the Poisson's ratio of the pulley material, dimensionless, and the value of bearing steel is 0.3; contace is the contact coefficient, dimensionless, ranging from 1.1 to 1.3, taking into account the contact stress concentration effect.

[0099] Calculation of dimensional changes caused by temperature changes:

[0100] ΔD thermal =Δ thermal ·(T max -T min )·D pulley ;

[0101] Where, α thermal is the linear expansion coefficient, the unit is 1 / degree Celsius, and the value of bearing steel is 1.2×10^(-5); T max is the maximum operating temperature, in degrees Celsius, with a value of 50; T min The minimum operating temperature is in degrees Celsius and is -20.

[0102] Consider the relationship between the pulley running resistance and the clearance:

[0103] F friction =μ bearing ·F load (1+k G ·G -1 );

[0104] Where, F friction is the pulley running resistance, in Newtons; μ bearing is the friction coefficient of the pulley bearing, dimensionless, and its value is 0.05; k G is the gap influence coefficient, the unit is mm, and the value range is 0.2-0.5.

[0105] The parameter acquisition method is:

[0106] D pulley and D rope Directly measure with precision measuring tools; E pulley and μ pulley Obtained from the material manual; α thermal Obtained through the material manual; T max and T min Determined according to the engineering application environment; μ bearing Obtained through bearing specification query; K contact and k G The experimental method is to measure the pulley deformation and running resistance under different loads and obtain them through data fitting.

[0107] The pulley assembly matching equation is based on contact mechanics theory and thermal expansion principle, and is designed to ensure that the gap between the pulley and the wire rope is appropriate, so that neither the gap is too small to cause jamming nor the gap is too large to cause increased shaking. -1 The term (the value of the coefficient of friction) reflects the physical phenomenon of rapidly increasing frictional resistance as the gap decreases. The novelty of this equation lies in its comprehensive consideration of two key influencing factors: load deformation and temperature change. It also establishes a quantitative relationship between gap and operating resistance, providing a theoretical basis for pulley design.

[0108] The protection height calculation equation is used to determine the minimum height of the hanging basket enclosure system, which is specifically expressed as follows:

[0109] H guard =H person ·C posture +A swing +H tool +H safety ;

[0110] Where H guard is the minimum height of the enclosure system, in cm, the calculated result is 118.75 cm, and the design value is 120 cm; person is the average height of operators, in cm. The average height of Chinese adult males is 175 cm. posture A is the height coefficient of the working posture, dimensionless, considering the working postures such as bending over and raising the head, and the value is 1.15; swing The maximum swing amplitude of the hanging basket is in cm. The value determined by dynamic test is 10cm. tool H is the maximum height of the working tool, in cm, with a value of 30 cm; safety It is the safety redundancy height in cm, and the value is 15cm.

[0111] Considering the influence weight of each parameter, it is further refined as follows:

[0112] H guard =w1·H person ·C posture +w2·A swing +w3·H tool +w4·H safety ;

[0113] Where w1, w2, w3, and w4 are dimensionless weight coefficients that reflect the degree of influence of each factor on the enclosure height. They are determined by expert evaluation and are 0.4, 0.25, 0.2, and 0.15, respectively, and meet the following requirements:

[0114] For special working conditions, the working condition adjustment coefficient is introduced:

[0115]

[0116] Where, is the height of the enclosure after adjustment, in cm; C condition It is the working condition adjustment coefficient, dimensionless, and takes the value of 1 for standard working conditions and 1.25 for special working conditions such as strong wind environment.

[0117] The parameter acquisition method is:

[0118] H person Obtain the height statistics of the target population through the anthropometric database; C posture Determined by ergonomic measurement, the measurement method is to record the ratio of the highest point of the human body to the standing height in different working postures; A swing Determined by the dynamic test of the hanging basket, the test method is to measure the maximum swing amplitude of the hanging basket under simulated working conditions; Htool is determined by measuring the size of commonly used tools; H safety Determined according to safety regulations; w1 to w4 are determined by collecting expert opinions through the Delphi method; C condition Determine the safety factor under different working conditions through risk assessment.

[0119] The protective height calculation equation is based on ergonomic principles and safety redundancy design, comprehensively considering the operator's physiological characteristics, operational characteristics, environmental factors, and safety requirements. The linear combination method is simple and practical, and the weight coefficients reflect the relative importance of each factor. The practical value of this equation lies in providing a scientific basis for the design of hanging basket enclosure systems, ensuring operator safety in high-altitude working environments while not excessively increasing the structure height and affecting operational efficiency.

[0120] The load distribution balance equation is used to calculate the force values ​​at the four connection points of the hanging basket to ensure that the forces at each connection point are balanced. The specific expression is as follows:

[0121]

[0122] Where, F i is the force value of the i-th connection point, i = 1, 2, 3, 4, the unit is Newton; W total is the total weight in Newtons, which is the sum of the weight of the hanging basket, the weight of the workers and the weight of the working materials, that is, (160+150+100) kg multiplied by the acceleration due to gravity; is the additional force caused by uneven weight of the hanging basket, the unit is Newton; is the additional force caused by uneven material distribution, the unit is Newton; is the additional force caused by the personnel position, in Newtons; It is the additional force caused by wind load, in Newton.

[0123] The additional forces are calculated as follows:

[0124]

[0125] Where W basket is the weight of the hanging basket, in Newtons, and is 160kg multiplied by the acceleration of gravity; x G ,y G is the coordinate of the center of gravity of the hanging basket, in meters; x i ,y i is the coordinate of the i-th connection point, in meters; I x , I y is the moment of inertia of the connection point distribution, in meters^2.

[0126]

[0127] Where, is the weight of the jth portion of material, in N; is the coordinate of the center of gravity of the jth material, in meters; n M The number of material partitions.

[0128]

[0129] Where, is the weight of the kth person, in units of oxen, and is 75 kg / person multiplied by the acceleration due to gravity; is the kth person's position coordinate, in meters; n P The number of people is 2.

[0130]

[0131] Where, F wind is the wind load, in Newton, calculated as 102.7 Newton at level 8 wind speed; h wind is the height of wind load, in meters; x C is the horizontal coordinate of the center of the hanging basket, in meters.

[0132] Calculate the force difference of the connection point:

[0133]

[0134] Where η is the force difference, dimensionless, expressed as a percentage, and the design target requirement is less than 20%.

[0135] The parameter acquisition method is:

[0136] W basket 、 and Obtained by weighing; x G and y GDetermine the center of gravity of the hanging basket through the lifting test; i 、y i 、 and Obtained by coordinate measurement; F wind Calculated based on wind speed and windward area: Where ρ is the air density (1.29 kg / m3), v is the wind speed (20 m / s for level 8 wind), C d is the drag coefficient (1.2), A is the frontal area (square meters); h wind The equivalent action height is determined through wind tunnel tests.

[0137] The load distribution balance equation is based on the principles of static equilibrium and structural mechanics theory. It ensures the balance of the hanging basket by calculating the forces at each connection point. The equation takes into account four main load factors: the weight of the hanging basket, material distribution, occupant position, and wind load, and reflects the influence of the connection point layout on the force distribution through the moment of inertia. The product relationship (such as the position offset product term) reflects the law of torque transmission, and the fractional relationship reflects the mechanism of force balance. The value of this equation lies in guiding the optimization design of the connection points through quantitative calculation, reducing force differences, and preventing the hanging basket from tilting or shaking excessively due to uneven load distribution during use.

[0138] The calculation equation of the mobile control force is used to determine the minimum control force required to move the hanging basket, which is specifically expressed as follows:

[0139] F control =F static (1+k start )·cosθ rope ;

[0140] Where, F control F is the force required for movement control, in Newtons, and the calculated result is 172 Newtons; static is the static equilibrium force, in Newtons; k start is the startup additional coefficient, dimensionless, with a value of 0.25; θ rope It is the angle between the auxiliary wire rope and the moving direction, measured in degrees, and the design value is 30 degrees.

[0141] Static equilibrium force calculation:

[0142] F static =μ bearing W total ·cosα+W total sinα+C damp ·v;

[0143] Where μ bearing is the friction coefficient of the pulley bearing, dimensionless, and its value is 0.15; W totalis the total weight of the hanging basket, in Newtons, and its value is 410kg multiplied by the acceleration of gravity; α is the inclination angle of the wire rope, in degrees, and its value is 5 degrees; C damp is the damping coefficient, the unit is Newton-second / meter, and the value is 0.25; v is the moving speed of the hanging basket, the unit is meter / second, and the standard operating speed is 0.2 meter / second.

[0144] Considering the winch transmission efficiency:

[0145]

[0146] Where, F handle The force applied to the handle end is in Newtons, and the calculated result is 46 Newtons; r drum is the radius of the winch drum, in meters, and the value is 0.075 meters; i gear is the transmission ratio, dimensionless, and its value is 30; η gear is the transmission efficiency, dimensionless, and its value is 0.85; l handle The length of the handle is in meters, and the value is 0.4 meters.

[0147] In order to evaluate the change of control force under different conditions, a parameter sensitivity matrix is ​​established:

[0148]

[0149] By calculating the sensitivity matrix, the influence of each parameter on the control force can be determined to guide the design optimization.

[0150] The parameter acquisition method is:

[0151] μ bearing Obtained from the bearing parameter manual; W total The total weight of the hanging basket is obtained by weighing; α uses an inclinometer to measure the inclination of the wire rope; C damp Determined by dynamic testing, the test method is to measure the resistance at different speeds and fit the damping coefficient; k start Determined by starting test, the test method is to measure the ratio of starting force to stable running force; θ rope Determined by geometric measurements; r drum 、i gear ,η gear and l handle Obtained through winch parameters and actual measurements.

[0152] The equation for calculating the motion control force is based on the principles of mechanical transmission and friction mechanics, taking into account three primary influencing factors: static friction, gravity, and dynamic damping. The cosine function reflects the directional decomposition of the force, while the linear combination reflects the superposition of different resistance factors. The practical value of this equation lies in providing a theoretical basis for winch design, ensuring convenient single-person operation. Furthermore, a sensitivity matrix is ​​used to analyze the influence of various parameters, guiding design optimization.

[0153] The sway suppression function is used to optimize the design of the safety protection device and reduce the sway amplitude of the hanging basket during use. The specific expression is as follows:

[0154] A(t)=A0e -ζωt cos(ω d t+φ);

[0155] Where A(t) is the sway amplitude at time t, in cm; A0 is the initial sway amplitude, in cm; ζ is the damping ratio, dimensionless, with an optimal value of 0.25; ω is the natural frequency of the system, in radians per second; ω d is the damped vibration frequency in radians per second, φ is the phase angle in radians.

[0156] Calculation of system natural frequency:

[0157]

[0158] Where, T is the wire rope tension, in Newtons, and its value is 25,000 Newtons; α is the wire rope inclination, in degrees, and its value is 5 degrees; W total is the total weight of the hanging basket, in Newtons, and is 410 kg multiplied by the acceleration of gravity; L effective is the effective hanging length in meters.

[0159] The relationship between the maximum shaking amplitude and wind speed:

[0160]

[0161] Where A max (v) is the maximum sway amplitude under wind speed v, in cm; k v is the wind speed influence coefficient, the unit is second 2 / meter 2, the value is 0.02; v is the wind speed, the unit is meter / second; A ref The reference shaking amplitude is in cm and the value is 10cm.

[0162] The impulse response function considering the impact of personnel movement:

[0163]

[0164] Where Aimpact (t) is the shaking amplitude caused by the impact, in cm; F impact is the impact force generated by the movement of personnel, in Newtons; m is the mass of the hanging basket, in kilograms, and the value is 410kg.

[0165] Overall sway control objective function:

[0166]

[0167] Where J(ζ) is the objective function that needs to be minimized; w1, w2, and w3 are weight coefficients that reflect the importance of the maximum sway amplitude, the accumulated sway energy, and the complexity of the damper, respectively; v design is the design wind speed, in meters per second, and the value is 20 meters per second; t settle The expected shake decay time in seconds.

[0168] The parameter acquisition method is:

[0169] T uses a tensiometer to measure the wire rope tension; α uses an inclinometer to measure the wire rope inclination; W total Obtained by weighing; L effective Determined by actual measurement; k v Determined by wind tunnel test, the test method is to measure the swing amplitude of the hanging basket at different wind speeds and fit the relationship curve; F impact It is determined through personnel movement testing. The test method is to simulate the rapid movement of workers on the hanging basket and measure the impact force generated. The weight coefficients of w1, w2 and w3 are determined by the multi-objective optimization method.

[0170] The sway suppression function, based on vibration dynamics theory, uses an exponentially decaying cosine function to describe the damped vibration characteristics, taking into account two primary excitation sources: wind load and occupant movement. The exponential term reflects the energy dissipation pattern, the cosine term reflects the periodic vibration characteristics, and the square term reflects the energy calculation method. The innovation of this method lies in establishing an optimization objective function that comprehensively considers both static and dynamic excitations. By solving for the optimal damping ratio, it guides the selection of damper design parameters, effectively reducing the sway amplitude during basket operation and improving user safety and comfort.

[0171] The multi-point stability balance function is used to optimize the connection system design and improve the stability of the hanging basket under various load conditions. It is specifically expressed as follows:

[0172]

[0173] Where P(X) is the stability evaluation function, dimensionless, the smaller the better; X is the connection point position matrix, X = [x1, y1, x2, y2, x3, y3, x4, y4], in meters; F j (X, Li ) is the force on the jth connection point under the i-th load condition, in Newtons; F max The design bearing capacity of the connection point is in Newtons, which is 500 kg multiplied by the acceleration of gravity; n load is the number of load cases considered.

[0174] The force calculation takes into account the load distribution under each working condition and expands the load distribution equilibrium equation:

[0175]

[0176] Where W k is the kth concentrated load, in Newtons; x k ,y k is the coordinate of the kth load action point, in meters; x j ,y j is the coordinate of the jth connection point, in meters; θ i is the offset angle under the i-th working condition, in degrees; D(X) is the characteristic value of the connection point distribution, in meters^2; n f is the number of concentrated loads.

[0177] Distribution eigenvalue calculation:

[0178]

[0179] Where x c ,y c is the center coordinate of the connection point, in meters,

[0180] Stability evaluation considering dynamic conditions:

[0181]

[0182] Where, P dyn (X) is the dynamic stability evaluation function, dimensionless; γdy n is the dynamic impact weight coefficient, dimensionless, and its value is 1.3; T is the evaluation time period, in seconds; F j (X, t) is the force on the j-th connection point at time t, in Newtons.

[0183] Introducing environmental wind load influence:

[0184]

[0185] Where, is the additional force on the jth connection point under wind load, in Newtons; C wind is the wind load coefficient, in N·s2 / m4, with a value of 0.05; v is the wind speed, in m / s; Aproj is the windward projected area in square meters; θ is the wind direction angle in degrees.

[0186] Optimization objective function:

[0187]

[0188] Where J(X) is the comprehensive evaluation function that needs to be minimized; w1, w2, and w3 are dimensionless weight coefficients with values ​​of 0.4, 0.4, and 0.2, respectively.

[0189] The parameter acquisition method is:

[0190] W k Obtain each concentrated load by weighing; x k 、y k The position of the load action point is obtained by coordinate measurement; θ i Determine the offset angle under each working condition through working condition analysis; γ dyn Determined by dynamic load test; C wind Determined by wind tunnel test; A proj The frontal area is calculated through geometric measurement; the weight coefficients of w1, w2 and w3 are determined by multi-objective decision-making method.

[0191] The multi-point stability balance function, based on multibody dynamics theory and topology optimization methods, optimizes the connection point layout by constructing stability evaluation functions under static and dynamic conditions. The minimum-maximum operation reflects the principle that the most unfavorable operating condition determines overall stability, the square term reflects the energy accumulation during the dynamic process, and the comprehensive evaluation function embodies the concept of multi-objective optimization. The innovation of this method lies in integrating static force balance, dynamic response characteristics, and environmental wind load influences into a unified optimization framework. Numerical optimization methods are used to solve the optimal connection point layout, thereby improving the stability of the hanging basket under various complex working conditions.

[0192] Specifically, the principle of the present invention is as follows: The technical principle of the present invention is based on mechanical balance, dynamic stability analysis and structural optimization design. Through the precise matching of a series of mathematical models and engineering parameters, the high stability and safety of the flexible photovoltaic support mobile hanging basket are achieved. The core technical principle can be explained from the following aspects:

[0193] First, the basket stability equation employed in this invention is based on the principle of moment balance. By calculating the combined effects of factors such as the basket's center of gravity, wire rope tension, total basket weight, wire rope inclination, and personnel offset distance, the basket's stability index is determined under various operating conditions. A value greater than 1.5 indicates the basket has sufficient safety margin to withstand external disturbances and maintain stability. This theoretical basis ensures the scientific and reliable nature of the basket design.

[0194] Secondly, the pulley assembly matching equation is based on contact mechanics and material deformation theory. By accurately calculating the optimal gap between the pulley and the wire rope (0.5-1.5mm), it ensures smooth operation of the pulley while avoiding the shaking caused by excessive gap. This precise matching relationship ensures the stability and positioning accuracy of the hanging basket when moving on the wire rope.

[0195] Furthermore, the load distribution balance equation utilizes the principle of static equilibrium, taking into account the effects of factors such as the basket's own weight, the weight of the crew, the weight of the materials, and wind load on the forces acting on the four connection points. By optimizing the location and structure of the connection points, it ensures balanced forces and prevents the basket from tilting and unstable shaking. This balance mechanism provides the basket with fundamental stability.

[0196] Furthermore, the sway suppression function and the multi-point stability balance function optimize the dynamic stability of the gantry from the perspectives of dynamic damping and multi-point balance, respectively. The former reduces vibration caused by external disturbances by calculating the optimal damping parameter configuration, while the latter improves the overall stability of the gantry under variable load conditions by optimizing the connection point layout.

[0197] Finally, the anti-fall locking mechanism, based on the principle of mechanical self-locking, automatically clamps the wire rope in the event of a main system failure, providing a safety guarantee independent of the main system. This dual protection mechanism fundamentally improves the safety and reliability of the hanging basket.

[0198] To sum up, the present invention combines engineering mechanics theory with actual engineering needs to establish a scientific and systematic method for designing and manufacturing mobile hanging baskets. Various parameters and components cooperate with each other and work together to ensure the stability and safety of the hanging basket from the theoretical and structural design levels, effectively solving the technical problems of insufficient stability and low safety of the mobile working hanging basket on the flexible photovoltaic bracket.

[0199] A specific embodiment 1 of the present invention is provided below. The specific implementation of each step in this embodiment 1 is described in detail as follows.

[0200] The specific implementation of step S01 is the same as above and will not be repeated here.

[0201] The specific implementation of step S02 is based on the principles of tribology and material mechanics. Bearing steel is used to make the pulley body. The pulley groove adopts a U-shaped design, and the groove depth is not less than 1.3 times the diameter of the wire rope. The inner diameter of the pulley is 16.5mm, forming a gap of 1.3mm between it and the 15.2mm wire rope. This gap value is calculated by the pulley assembly matching equation: G = D pulley -D rope -2ΔD deform -ΔD thermal , where G is the gap between the pulley and the wire rope, in mm, with an optimal range of 0.5 to 1.5 mm; Dpulley is the inner diameter of the pulley, in mm, and the initial design value is 16.5 mm; D rope is the wire rope diameter, in mm, the standard value is 15.2mm; ΔD deform is the deformation of the pulley under load, in mm; ΔD thermal It is the dimensional change caused by temperature change, in mm. This gap ensures that the pulley will not get stuck to the wire rope due to deformation when under load, and will not shake due to excessive gap. The pulley is supported by double-row angular contact ball bearings, and the dynamic load capacity of the bearings is not less than 5000 Newtons. Anti-slip guide devices are installed on both sides of the pulley. The guide device maintains a gap of 0.5mm to 1mm with the wire rope, which can prevent the wire rope from escaping the pulley groove when the pulley is tilted. The anti-slip guide device is made of polytetrafluoroethylene material to reduce the friction coefficient when in contact with the wire rope. Each hanging basket is equipped with 4 sets of main pulley groups and 2 sets of safety pulley groups. The main pulley group adopts a double pulley design to increase the contact area and reduce the pressure per unit area. This step is to ensure that the hanging basket can move smoothly on the wire rope and prevent it from escaping from the wire rope due to pulley failure.

[0202] The specific implementation of steps S03-S04 is the same as above and will not be repeated here.

[0203] The specific implementation of step S05 is to use 25mm×25mm×3mm angle steel to make the enclosure frame, and the enclosure height is 120cm, which is determined according to the protection height calculation formula: H guard =H person ·C posture +A swing +H tool +H safety , where H guard is the minimum height of the enclosure system, in cm, the calculated result is 118.75 cm, and the design value is 120 cm; person is the average height of operators, in cm. The average height of Chinese adult males is 175 cm. posture A is the height coefficient of the working posture, dimensionless, considering the working postures such as bending over and raising the head, and the value is 1.15; swing The maximum swing amplitude of the hanging basket is in cm. The value determined by dynamic test is 10cm. tool H is the maximum height of the working tool, in cm, with a value of 30 cm; safety= is the safety margin height, expressed in cm, with a value of 15 cm. This equation takes into account parameters such as an average worker height of 175 cm, a working posture height coefficient of 1.15 (the highest working posture is a stooped, head-up position), a maximum basket swing amplitude of 10 cm, a safety margin height of 15 cm, and a maximum tool height of 30 cm. The spacing between the columns of the enclosure frame is no more than 50 cm, with horizontal fences installed at the top and center. The enclosure system utilizes standard welded steel gratings with a mesh size of 50 mm x 100 mm. The gratings are connected to the frame using M8 bolts with spacing no greater than 30 cm. A 60 cm wide entrance is provided on one side of the enclosure system, with dual safety doors: a conventional hinged outer door and an inward-opening spring inner door, ensuring that at least one door is always closed. Conspicuous yellow and black warning signs are painted on the four corners and at the entrance of the enclosure system. This procedure is based on ergonomic principles and aims to ensure the personal safety of operators working at height, while also maintaining a good working field and improving work efficiency.

[0204] The specific implementation of step S06 is to determine the positions and stress conditions of the four connection points based on the load distribution equilibrium equation: Among them, F i is the force value of the i-th connection point, i = 1, 2, 3, 4, the unit is Newton; W total is the total weight in Newtons, which is the sum of the weight of the hanging basket, the weight of the workers and the weight of the working materials, that is, (160+150+100) kg multiplied by the acceleration due to gravity; is the additional force caused by uneven weight of the hanging basket, the unit is Newton; is the additional force caused by uneven material distribution, the unit is Newton; is the additional force caused by the personnel position, in Newtons; is the additional force due to wind load, measured in Newtons. The input parameters for this equation include the basket's own weight of 160 kg, the weight of the crew of 150 kg (assuming two people working simultaneously), the weight of the work material of 100 kg, the wind load calculated based on a wind speed of 102.7 Newtons at level 8, and the basket dimensions of 150 cm × 100 cm. Calculations show that the ideal location for the four connection points should be 10 cm inboard of the four corners of the frame. This location provides the most balanced force, with the force difference at the four points not exceeding 5%. High-strength lifting rings are installed at the connection points. The rings are made of 40Cr alloy steel, heat-treated to a hardness of HRC40 or higher. The safe working load of a single ring is no less than 500 kg. The rings are connected to the frame with M16 high-strength bolts, with a tightening torque of 180 N·m. The rings are connected to high-strength hooks, manufactured using a forging process and galvanized for corrosion protection. The hooks are equipped with a safety lock to prevent the pulley assembly from accidentally falling off during use. The connection system design follows the results of a multi-point stability balance function optimization, taking into account the basket's center of gravity, the expected maximum load distribution, a wire rope pretension of 25kN, a dynamic coefficient of 1.3 for the operating posture, and an ambient wind load coefficient of 1.8. This step, based on the principles of static equilibrium and structural mechanics theory, aims to ensure a reliable and stable connection between the pulley assembly and the basket body, evenly carrying the load and reducing basket tilt and sway.

[0205] The specific implementation method of step S07 is to install manual winch devices on both sides of the hanging basket. The maximum load-bearing capacity of the winch is not less than 500kg. It adopts a worm gear transmission structure with a transmission ratio of 1:30 to ensure easy operation and self-locking function. The winch is installed on the bracket, and the bracket is connected to the main frame of the hanging basket with M12 bolts. An auxiliary steel wire rope with a diameter of 8mm is wound on the winch. One end of the steel wire rope is fixed to the winch drum, and the other end is returned to the vicinity of the hanging basket through a fixed anchor point on the ground. The distance between the fixed anchor point and the main anchor points at both ends is 1.5 times the width of the hanging basket to ensure that there is a sufficient angle between the auxiliary steel wire rope and the main steel wire rope to increase the control force vector component. According to the mobile control force calculation equation: F control =F static (1+k start )·cosθ rope , where F control F is the force required for movement control, in Newtons, and the calculated result is 172 Newtons; static is the static equilibrium force, in Newtons; k start is the startup additional coefficient, dimensionless, with a value of 0.25; θ ropeThe angle between the auxiliary wire rope and the direction of movement is expressed in degrees, and the design value is 30 degrees. Calculations show that the minimum control force required to move the basket is 150 Newtons. The winch handle is 40 cm long, and the force required for single-person operation does not exceed 50 Newtons, meeting ergonomic requirements. The winch is equipped with a ratchet locking mechanism to ensure that the position of the basket does not change when the handle is released. This step is based on the principles of mechanical transmission and mechanical balance theory, with the aim of providing a reliable movement control method that allows the operator to easily control the movement of the basket along the wire rope direction and reliably dock at any position.

[0206] The specific implementation of steps S08-S09 is the same as above and will not be repeated here.

[0207] The specific implementation of step S10 is to apply the hanging basket stability equation to calculate the stability index of the hanging basket when it runs on the wire rope: Among them, SI is the stability index, dimensionless, and the safety requirement is greater than 1.5; M resist is the minimum anti-overturning moment, in Nm; M overturn is the maximum overturning moment, in N·m. Further expansion yields: Wherein, T is the wire rope tension value, the unit is Newton, and the measured value is 25000 Newton; d vert is the vertical moment arm, in meters, which is the vertical distance from the pulley block to the center of gravity of the basket; α is the angle between the wire rope and the horizontal plane, in degrees, and the measured value is 5 degrees; W is the total weight of the basket, in Newtons, which is 410 kg multiplied by the acceleration of gravity; d horiz is the horizontal moment arm, in meters, which is the horizontal distance from the center of gravity of the basket to the edge of overturning; β is the tilt angle of the basket, in degrees, which is close to 0 degrees under normal working conditions; F wind is the wind load, in Newton, calculated as 102.7 Newton at level 8 wind speed; h center W is the height of wind load, in meters, which is the height of the center of gravity of the hanging basket; person is the weight of the worker, in units of oxen, and is 75 kg / person multiplied by the acceleration due to gravity; d max is the maximum offset distance of the staff, in meters, with a value of 0.6 meters; γ dynis the dynamic load coefficient, dimensionless, and takes a value of 1.3. This equation is based on the principle of mechanical equilibrium and takes into account the effects of multiple forces, including gravity, wind, and dynamic loads. The input parameters include a wire rope tension of 25kN, a total basket weight of 410kg, the position of the basket's center of gravity (horizontally offset by 5cm and vertically offset by -20cm from the geometric center), a wire rope inclination of 5 degrees, and a maximum worker offset distance of 60cm. The calculation uses a numerical integration method, while also considering nonlinear factors such as the pulsating effect of wind loads and the impact coefficient of personnel movement. The calculation results show that under the most unfavorable operating conditions (a fully loaded basket, two workers simultaneously located on one edge, and a force 8 crosswind), the stability index is 1.78, meeting safety requirements. Parameter sensitivity analysis revealed that the distribution of worker positions has the greatest impact on stability. Therefore, in actual operating procedures, workers are required to avoid being on the same side of the basket at the same time. This step is based on mechanical equilibrium theory and stability analysis methods. The purpose is to verify the stability of the basket design through theoretical calculations to ensure that it will not capsize under various operating conditions.

[0208] The specific implementation of step S11 is to apply the pulley assembly matching equation to determine the optimal gap value between the pulley assembly and the wire rope: G = D pulley -D rope -2ΔD deform -ΔD thermal , where G is the gap between the pulley and the wire rope, in mm, with an optimal range of 0.5 to 1.5 mm; D pulley is the inner diameter of the pulley, in mm, and the initial design value is 16.5 mm; D rope is the wire rope diameter, in mm, the standard value is 15.2mm; ΔD deform is the deformation of the pulley under load, in mm; ΔD thermal The dimensional change caused by temperature change, in mm. Calculation of pulley deformation: Among them, F load is the expected maximum load, in Newtons, and is 615 kg multiplied by the acceleration due to gravity; R pulley is the pulley radius, in mm, which is half of the inner diameter; E pulley is the elastic modulus of the pulley material, in GPa, and the value for bearing steel is 210 GPa; μ pulley k is the Poisson's ratio of the pulley material, dimensionless, and the value of bearing steel is 0.3; contactis the contact coefficient, dimensionless, ranging from 1.1 to 1.3, taking into account the effect of contact stress concentration. This equation is based on contact mechanics theory and takes into account factors such as material elastic deformation and frictional thermal expansion. Input parameters include a wire rope diameter of 15.2 mm, an expected maximum load of 615 kg (1.5 times the design load), an initial pulley inner diameter, a pulley material elastic modulus of 210 GPa (bearing steel), and a pulley bearing friction coefficient of 0.05. The equation uses iterative calculations to analyze the relationship between the pulley's operating resistance and service life for different clearance values, ultimately determining the optimal clearance value of 1.3 mm. This value ensures that the pulley will not jam the wire rope due to elastic deformation of the material when fully loaded, while at the same time, the clearance is not too large to increase shaking. Based on this result, the pulley inner diameter is determined to be 16.5 mm. This step is based on contact mechanics theory and material deformation analysis methods. The purpose is to accurately determine the optimal matching relationship between the pulley and wire rope through calculation to ensure smooth and stable movement of the hanging basket.

[0209] The specific implementation of step S12 is to use the protection height calculation equation to determine the minimum height value of the hanging basket enclosure system: H grard =H person ·C posture +A swing +H tool +H safety , where H guard is the minimum height of the enclosure system, in cm, the calculated result is 118.75 cm, and the design value is 120 cm; person is the average height of operators, in cm. The average height of Chinese adult males is 175 cm. posture A is the height coefficient of the working posture, dimensionless, considering the working postures such as bending over and raising the head, and the value is 1.15; swing The maximum swing amplitude of the hanging basket is in cm. The value determined by dynamic test is 10cm. tool H is the maximum height of the working tool, in cm, with a value of 30 cm; safety is the safety redundancy height, in cm, with a value of 15cm. Considering the influence weight of each parameter, it is further refined as follows: H guard =w1·H person ·C posture +w2·A swing +w3·H tool +w4·H safety , where w1, w2, w3, and w4 are dimensionless weight coefficients that reflect the degree of influence of each factor on the enclosure height. They are determined by expert evaluation and are 0.4, 0.25, 0.2, and 0.15, respectively, and meet the following requirements: This equation is based on ergonomic principles and comprehensively considers operator safety and operational convenience. Calculation results show that the minimum height of the enclosure system should be 118.75cm, rounded to 120cm. This height can ensure that operators are effectively protected in various working postures, while not affecting the operator's field of view and work efficiency due to being too high. The actual design uses a modular enclosure system, which can adjust the height according to specific working conditions. The basic height is 120cm, and it can be increased to 150cm for special working conditions. This step is based on ergonomics and safety design theory, and its purpose is to determine the scientific height of the enclosure system to ensure operator safety without affecting work efficiency.

[0210] The specific implementation of step S13 is to apply the load distribution balance equation to calculate the force values ​​of the four connection points of the hanging basket to ensure that the force at each connection point is balanced: Among them, F i is the force value of the i-th connection point, i = 1, 2, 3, 4, the unit is Newton; W total is the total weight in Newtons, which is the sum of the weight of the hanging basket, the weight of the workers and the weight of the working materials, that is, (160+150+100) kg multiplied by the acceleration due to gravity; is the additional force caused by uneven weight of the hanging basket, the unit is Newton; is the additional force caused by uneven material distribution, the unit is Newton; is the additional force caused by the personnel position, in Newtons; is the additional force due to wind load, measured in Newtons. This equation is based on the principles of static equilibrium and finite element analysis. Input parameters include the basket's deadweight of 160 kg, the weight of a worker of 150 kg (assuming two people working simultaneously), the weight of the work material of 100 kg, a wind load calculated at level 8 wind speed of 102.7 Newtons, and a basket size of 150 cm x 100 cm. The equation accounts for center of gravity offset and dynamic loads, employing a rigid body dynamics model. Calculation results show that under the most unfavorable operating conditions (two workers simultaneously in one corner, with materials stacked on the same side), the maximum force difference at the four connection points is 29.3%, exceeding the design target by 20%. By adjusting the connection point position (moving it 5 cm toward the heavier load side) and the placement of reinforcement bars, the optimized force difference was reduced to 18.7%, meeting the design requirements. The four connection points were ultimately located 10 cm inboard of the four corners of the frame. Each connection point was designed to bear a load of 500 kg, with an actual maximum force of 320 kg, achieving a safety factor of 1.56. This step is based on the theory of static equilibrium and structural optimization methods, and its purpose is to ensure the suspension balance of the hanging basket through precise calculations, and to prevent the hanging basket from tilting or shaking too much due to uneven load distribution. By adjusting the position of the connection points (moving 5cm to the heavy-load side) and the arrangement of the reinforcement bars, the force difference after optimization is reduced to 18.7%, meeting the design requirements. The four connection points are finally determined to be 10cm from the inside of the four corners of the frame. The design bearing capacity of each connection point is 500kg, the actual maximum force is 320kg, and the safety factor reaches 1.56. This step is based on the theory of static equilibrium and structural optimization methods, and its purpose is to ensure the suspension balance of the hanging basket through precise calculations, and to prevent the hanging basket from tilting or shaking too much due to uneven load distribution.

[0211] The specific implementation of step S14 is to use the mobile control force calculation equation to determine the minimum control force value required to move the hanging basket, providing a basis for the design of the manual winch: control =F static (1+k start )·cosθ rope , where F control F is the force required for movement control, in Newtons, and the calculated result is 172 Newtons; static is the static equilibrium force, in Newtons; k start is the startup additional coefficient, dimensionless, with a value of 0.25; θ rope The angle between the auxiliary wire rope and the moving direction is in degrees, and the design value is 30 degrees. Static balance force calculation: F static =μ bearing W total ·cosα+W total sinα+C damp v, where μ bearing is the friction coefficient of the pulley bearing, dimensionless, and its value is 0.15; W totalis the total weight of the hanging basket, in Newtons, and its value is 410kg multiplied by the acceleration of gravity; α is the inclination angle of the wire rope, in degrees, and its value is 5 degrees; C damp is the damping coefficient, in Newton-second-per-meter, with a value of 0.25; v is the basket movement speed, in meters per second, with a standard operating speed of 0.2 meters per second. This equation is based on the principles of mechanical transmission and friction mechanics, taking into account three main influencing factors: static friction, gravity component, and dynamic damping. Calculation results show that the minimum control force required to start the basket when stationary is 172 Newtons, and the control force required to maintain movement in motion is 138 Newtons. The larger value of 172 Newtons is taken as the design value. Based on this control force, the winch transmission ratio is designed to be 1:30, the handle length is 40 cm, and the force applied by a single operator at the handle end is approximately 46 Newtons, which meets ergonomic standards (single-person continuous operating force does not exceed 50 Newtons). The winch drum diameter is 150 mm, and the basket moves approximately 16 cm per rotation, facilitating precise position control. This step is based on mechanical balance and mechanical transmission theory, with the aim of ensuring that the basket movement control system is reasonably designed and easy to operate and controllable.

[0212] The specific implementation of step S15 is to optimize the design of the safety protection device by applying the sway suppression function to reduce the sway amplitude of the hanging basket during use: A(t) = A0e -ζωt cos(ω d t+φ), where A(t) is the sway amplitude at time t, in cm; A0 is the initial sway amplitude, in cm; ζ is the damping ratio, dimensionless, with an optimal value of 0.25; ω is the natural frequency of the system, in radians per second; ω d is the damped vibration frequency in radians per second, φ is the phase angle in radians. Calculation of the system's natural frequency: Where, T is the wire rope tension, in Newton, with a value of 25,000 Newtons; α is the wire rope inclination, in degrees, with a value of 5 degrees; W total is the total weight of the hanging basket, in Newtons, and is 410 kg multiplied by the acceleration of gravity; L effectiveis the effective suspension length in meters. This function is based on vibration dynamics theory and damping control principles. Input parameters include a wire rope tension of 25 kN, a basket weight of 410 kg, wind speed (considering force 6 winds of 20.8 to 24.4 m / s), operator movement frequency (on average, one large movement every 30 seconds), and a damping coefficient (initial value 0.15). The function uses a multivariable optimization algorithm to analyze the impact of different damping device parameters on the system's vibration response and identify the optimal damping configuration. Calculations show that the optimal damping coefficient is 0.25, which reduces the maximum basket sway amplitude from 18.6 cm in the unoptimized condition to 10.2 cm. Based on these results, two sets of hydraulic dampers were installed, located diagonally across the basket. The damping force varies nonlinearly with displacement velocity, with low damping force at low speeds (allowing the operator to move without noticeable resistance) and high damping force at high speeds (effectively suppressing sudden sway). The dampers are temperature-compensated to ensure stable performance within the temperature range of -20°C to 50°C. This step is based on vibration control theory and optimal control methods. Its purpose is to optimize the design of the damping device through scientific calculations to improve the stability and operating comfort of the hanging basket.

[0213] The specific implementation of step S16 is to apply a multi-point stability balance function to optimize the connection system design to improve the stability of the hanging basket under various load conditions: Where P(X) is the stability evaluation function, dimensionless, the smaller the better; X is the connection point position matrix, X = [x1, y1, x2, y2, x3, y3, x4, y4], in meters; F j (X, L i ) is the force on the jth connection point under the i-th load condition, in Newtons; F max The design bearing capacity of the connection point is in Newtons, which is 500 kg multiplied by the acceleration of gravity; n load is the number of load cases considered. The load distribution under each condition is considered in the force calculation, and the load distribution equilibrium equation is expanded: Among them, W k is the kth concentrated load, in Newtons; x k ,y k is the coordinate of the kth load action point, in meters; x j ,y j is the coordinate of the jth connection point, in meters; θ i is the offset angle under the i-th working condition, in degrees; D(X) is the characteristic value of the connection point distribution, in meters 2 ;n fis the number of concentrated loads. This function is based on multibody dynamics theory and topology optimization methods. Its input parameters include the center of gravity of the basket (horizontally offset by 5 cm and vertically offset by -20 cm from the geometric center), the expected maximum load distribution (based on the calculation results of step S13), a wire rope pretension of 25 kN, a dynamic coefficient of 1.3 for the working posture, and an ambient wind load coefficient of 1.8. The function establishes a coupled dynamic model of the basket, connection system, and wire rope to simulate and analyze the stability of the system under different connection point layouts. The optimization goal is to minimize the maximum sway amplitude under various operating conditions. Calculation results show that compared to the initial design (connection points located at the four corners of the frame), the optimized connection point layout (offset inward by 10 cm and adjusted 5 cm toward the center of gravity) can reduce the maximum sway amplitude by 23.5%. Furthermore, the optimization includes adding damping components to the connection system and using composite shock-absorbing pads to reduce impact load transmission. The final connection system design uses these adjusted connection point positions, combined with high-strength connectors and shock-absorbing devices, to maximize stability while ensuring load-bearing capacity. This step is based on multi-objective optimization theory and stability analysis methods. Its purpose is to improve the overall structural stability, reduce shaking, and enhance safety and comfort in use by optimizing the design of the connection system.

[0214] To sum up, the manufacturing method of the flexible photovoltaic bracket mobile hanging basket provided in this embodiment is a multidisciplinary integration, combining advanced technologies such as structural mechanics, material mechanics, vibration control, and optimization theory. Through precise mathematical models and scientific calculation methods, it ensures the safety, stability and ease of operation of the hanging basket in actual use.

[0215] It should be noted that the variables involved in the present invention are explained in detail as shown in Table 1-2 below.

[0216] Table 1 Variable explanation table a

[0217]

[0218]

[0219] Table 2 Variable explanation table b

[0220]

[0221] The above description is only a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with this technical field can easily think of changes or replacements within the technical scope disclosed by the present invention, which should be covered by the scope of protection of the present invention.

Claims

1. A method for manufacturing a mobile hanging basket for a flexible photovoltaic support, characterized in that: include: Prepare the wire rope suspension system; Make a hanging basket to connect the hanging parts; Make the main structure of the hanging basket; weld the bearing platform at the bottom of the hanging basket frame; Installing the gondola containment system; Connect the pulley assembly to the main body of the hanging basket; install the mobile control system; set up the safety protection device; conduct an overall load test; apply the hanging basket stability equation to calculate the stability index of the hanging basket when it is running on the wire rope, and determine whether the stability of the hanging basket meets the safety requirements based on the wire rope tension value, the total weight of the hanging basket, the position of the center of gravity of the hanging basket, the inclination angle of the wire rope and the maximum offset distance of the staff; apply the pulley assembly matching equation to determine the gap value between the pulley assembly and the wire rope; apply the protection height calculation equation to determine the minimum height value of the hanging basket enclosure system; apply the load distribution balance equation to calculate the force values ​​at the four connection points of the hanging basket; apply the mobile control force calculation equation to determine the minimum control force value required to move the hanging basket; apply the sway suppression function to optimize the design of the safety protection device; apply the multi-point stability balance function to optimize the design of the connection system.

2. The method for manufacturing a mobile hanging basket for a flexible photovoltaic support according to claim 1, characterized in that: The preparation of the wire rope suspension system specifically refers to fixing a steel wire rope with a diameter of 15.2 mm at the anchor points at both ends of the flexible photovoltaic bracket to ensure that the wire rope tension is appropriate and firmly fixed; the wire rope suspension system specifically refers to a support system composed of an anchoring device, prestressed steel wire rope and tensioning equipment, which is used to provide a walking track and support bearing capacity for the mobile hanging basket.

3. The method for manufacturing a mobile hanging basket for a flexible photovoltaic support according to claim 2, characterized in that: The production of the hanging basket connecting the suspension part specifically refers to the use of a high-strength pulley assembly, the inner diameter of the pulley is slightly larger than the diameter of the wire rope, and limit devices are set on both sides of the pulley assembly to prevent it from escaping from the wire rope; the high-strength pulley assembly specifically refers to a rolling bearing pulley that can withstand a load of not less than 3000 Newtons, the pulley groove type matches the wire rope diameter, and anti-slip groove guide devices are provided on both sides.

4. The method for manufacturing a mobile hanging basket for a flexible photovoltaic support according to claim 3, characterized in that: The production of the main structure of the hanging basket specifically refers to the use of 25mm square tubes to weld them into a rectangular frame with a frame size of 150cm×100cm, and 45-degree diagonal braces are added at the four corners to enhance the overall rigidity; the main structure of the hanging basket specifically refers to a working platform frame welded from 25mm square tubes, including a main frame, reinforcing ribs, connecting nodes and guardrails, which constitute a platform for workers to stand and place materials; the welding of a bearing platform at the bottom of the hanging basket frame specifically refers to the use of anti-slip steel plates, and 10cm high anti-slip edges are welded around the platform to prevent tools from slipping; the installation of the hanging basket enclosure system specifically refers to the use of 120cm high standard steel grilles on all sides to ensure the safety of operators while maintaining a good field of vision; the connection of the pulley assembly with the hanging basket body specifically refers to setting connection points at the four corners of the top of the hanging basket, and reliably connecting the pulley assembly to the hanging basket through high-strength hooks.

5. The method for manufacturing a mobile hanging basket for a flexible photovoltaic support according to claim 4, characterized in that: The installation of the mobile control system specifically refers to setting up manual winch devices on both sides of the hanging basket, connecting the hanging basket with fixed anchor points through steel wire ropes to enable the hanging basket to move along the direction of the steel wire rope; the mobile control system specifically refers to a device that retracts and releases the steel wire rope through a manual winch to move the hanging basket along the direction of the main steel wire rope, including a winch, an auxiliary steel wire rope, a guide pulley and a fixed anchor point; the setting of the safety protection device specifically refers to installing a safety pulley group independent of the main pulley system, equipped with an anti-fall locking mechanism, which automatically locks the steel wire rope when the main system fails; the anti-fall locking mechanism specifically refers to a mechanical device for automatically clamping the steel wire rope when the main pulley system fails or the moving speed exceeds the safety threshold to prevent the hanging basket from falling suddenly.

6. The method for manufacturing a mobile hanging basket for a flexible photovoltaic support according to claim 5, characterized in that: The basket stability equation specifically refers to a mathematical relationship used to calculate the stability index of the basket when it is running on a wire rope. Its input includes the measured wire rope tension value, the determined total weight of the basket, the determined center of gravity position of the basket, the measured wire rope inclination angle, and the maximum offset distance of the staff determined according to the operation requirements. The output is the basket stability index, which is used to determine whether the basket design meets the safety and stability requirements.

7. The method for manufacturing a mobile hanging basket for a flexible photovoltaic support according to claim 6, characterized in that: The pulley assembly matching equation specifically refers to a mathematical relationship used to determine the optimal matching relationship between the pulley assembly and the wire rope. Its input includes the measured wire rope diameter, the determined expected maximum load, the determined pulley inner diameter, the elastic modulus provided by the pulley material specification, and the friction coefficient provided by the pulley bearing specification. The output is the gap value between the pulley assembly and the wire rope, which is used to guide the selection and processing of the pulley assembly.

8. The method for manufacturing a mobile hanging basket for a flexible photovoltaic support according to claim 7, characterized in that: The protective height calculation equation specifically refers to a mathematical relationship used to determine the minimum height of the hanging basket enclosure system. Its input includes the average height of operators provided by the operator height statistics, the calculated maximum swing amplitude of the hanging basket, the working posture height coefficient determined by the working requirements, the safety redundancy height required by the safety regulations, and the maximum height of the working tool determined by the working tool specifications. The output is the minimum height value of the enclosure system, which is used to guide the design and installation of the enclosure system.

9. The method for manufacturing a mobile hanging basket for a flexible photovoltaic support according to claim 8, characterized in that: The load distribution balance equation specifically refers to a mathematical relationship used to calculate the force distribution at the four connection points of the hanging basket. Its input includes the determined deadweight of the hanging basket, the weight of the staff specified in the operation requirements, the weight of the working materials determined by the operation material list, the wind load parameters provided by the meteorological data, and the determined size parameters of the hanging basket. The output is the force values ​​of the four connection points, which are used to guide the design and layout of the connection points.

10. The method for manufacturing a mobile hanging basket for a flexible photovoltaic support according to claim 9, characterized in that: The movement control force calculation equation specifically refers to a mathematical relationship used to determine the minimum control force required to move the basket. Its input includes the determined total weight of the basket, the measured wire rope tension, the friction coefficient between the wire rope and the pulley provided in the material specification, the measured wire rope inclination angle, and the determined basket motion damping coefficient. The output is the minimum control force value required to move the basket, which is used to guide the selection and design of the manual winch.

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