Large equipment hoisting device and method

Abstract

The invention discloses a large equipment hoisting device and method, belongs to the technical field of engineering hoisting machinery, and solves the problems of attitude imbalance and low manual adjustment efficiency caused by gravity center shift. According to the technical scheme, a T-shaped guide rail groove and a slidable main lifting lug are arranged on the top face of a balance beam, and first to third lifting points are symmetrically arranged at the two ends; the hydraulic system is integrated in the beam to drive the main lifting lug to move; the first hoisting assembly is hinged with a first hoisting point and a first equipment lifting lug; the second hoisting assembly is connected with a second hoisting point, a third hoisting point and a second equipment lifting lug through a hoisting belt and an electric chain block; the closed-loop control system monitors the beam end load difference through the longitudinal pressure sensor, the transverse pressure sensor monitors the equipment lifting lug load difference, the self-adaptive adjusting module automatically controls the displacement of the hydraulic cylinder or the rotation angle of the chain block according to the longitudinal and transverse load difference value, and bidirectional unbalance correction is achieved. The device is mainly used for accurate and safe hoisting of large-scale equipment.

Description

Technical Field

[0001] The present invention relates to the technical field of engineering hoisting machinery, and in particular to a large equipment hoisting device and method. Background Art

[0002] During the lifting process of large equipment, the actual center of gravity of the equipment deviates from the theoretically calculated position, often resulting in an unbalanced lifting posture. Traditional lifting devices use a fixed-structure balance beam, and its lifting point position cannot be dynamically adjusted according to the actual load distribution. Operators need to rely on experience to repeatedly adjust the length of the sling or the position of the mobile crane. The adjustment process is time-consuming and has limited accuracy. This inefficiency stems from the shortcomings of existing monitoring methods. Pressure sensors are usually installed at indirect measurement points such as hooks or wire ropes. It is difficult to accurately obtain the true bearing stress at the root of the equipment's lifting lugs, resulting in a deviation between the feedback data and the actual load status.

[0003] In a hoisting environment with limited space, controlling the safe gap between the bottom surface of the equipment and surrounding obstacles is challenging. Operators need to observe the tilt state of the equipment and the bottom surface gap distance at the same time. Manual judgment is prone to visual errors, increasing the risk of collision. Existing anti-collision methods mainly rely on reducing the lifting speed and manual monitoring, but lack the ability to quantitatively analyze the dynamic relationship between the spatial posture of the equipment and the distance to the obstacle. When the equipment tilts slightly, the speed of manual risk identification and response is slow, and the time window from the equipment tilting to contacting the obstacle is short. This problem is related to the independent operation of the posture monitoring system and the distance detection system, and the data from the two systems fail to effectively coordinate.

[0004] The release of residual stress during the disassembly phase presents a safety hazard. Traditional operations involve directly disassembling the shackle connector. If the weight of the equipment is not fully transferred to the foundation, significant impact loads may be generated at the moment of disassembly, causing equipment displacement or damage to the connection structure. Attempts to alleviate this problem by manually releasing the fall chain are difficult to match with the rate of weight release of the equipment due to the lack of real-time monitoring of the axial load at the connection point, and additional dynamic loads may still be generated. Accurately determining the critical point of stress release presents technical difficulties.

[0005] The balance beam recovery process involves high-altitude operations, often requiring operators to climb to the top of the equipment to manually hook the beam. The success rate of hooking is limited by positioning accuracy, requiring repeated adjustments when deviations are significant. During load transfer, the coordination of the primary and secondary hooks relies on manual operation. Improper speed control can cause the balance beam to tilt, posing a risk of tipping over. Existing magnetic devices have a short effective range and require precise, close-range alignment for attachment, making them difficult to meet the demands of fast and safe recovery.

[0006] Solving these problems presented multiple challenges. High-precision sensors had a slow response speed, making it difficult to meet the time requirements for real-time adjustments during the lifting process. When the hydraulic system and actuators such as the electric chain-reverse operated independently, bidirectional adjustments could easily lead to system instability. The coupling relationship between equipment posture, clearance distance, and motion speed in confined spaces was complex, and a universal analytical model was lacking. In scenarios such as high-altitude disassembly, manual operation had objective limitations in terms of precision and response speed. These factors collectively hindered improvements in the safety and efficiency of large-scale equipment lifting. Summary of the Invention

[0007] The present invention provides a large-scale equipment lifting device and method, aiming to address the issues of posture imbalance caused by center of gravity shift during large equipment lifting, the inability of conventional devices to monitor the load at the base of the equipment lifting lugs in real time and automatically correct for longitudinal and transverse deviations, and the low efficiency and insufficient precision of manual adjustment. The present invention also addresses the cumbersome emergency operation when the electric fall chain loses power, the severe wear and tear caused by direct friction between the lifting strap and the equipment lifting lugs, and the reduced component life. The present invention also addresses the lack of a quantitative correlation between the guide rail slot length, hydraulic cylinder stroke, and fall chain dimensions, which can easily lead to structural failure due to spatial redundancy or interference. The present invention also addresses the issue of a fixed adjustment strategy causing system oscillation or response delay when the longitudinal and transverse load differences simultaneously approach thresholds. The present invention also addresses the issue of the failure to predict the center of gravity shift direction before lifting, the potential for manual clearance monitoring errors during lifting in confined spaces, and the increased risk of stress release due to an unreasonable disassembly sequence. The present invention also addresses the issue of the lack of a quantitative correlation between equipment tilt and distance to obstacles in confined spaces, resulting in insufficient manual response speed and potential collisions. The present invention also addresses the issue of excessive impact loads during shackle removal, which can easily cause equipment displacement or damage, and the lack of a staged unloading mechanism. The present invention also addresses the issue of the need for manual overhead hooking during balance beam recovery, resulting in the risk of overturning due to asynchronous load transfer between the main and auxiliary hooks. This solution addresses issues such as pitch / roll imbalance of the balance beam during load transfer, and the lack of linkage between overhead crane correction and hydraulic adjustment. It also addresses issues such as mechanical lag in hydraulic or correction actions not being compensated in real time, and the lack of visual verification of equipment position deviation and changes in obstacle distance.

[0008] In order to achieve these purposes and other advantages according to the present invention, a large equipment lifting device is provided, comprising: The balance beam has a T-shaped guide groove along its top surface along its length, a T-shaped slider is slidably fitted on the T-shaped guide groove, and a main lifting lug is provided on the T-shaped slider. The first lifting point, the second lifting point, and the third lifting point are symmetrically provided at both ends of the balance beam; The hydraulic drive system is integrated into the balance beam and includes a hydraulic cylinder and a controller. The cylinder body of the hydraulic cylinder is fixed inside the balance beam, and the end of the piston rod is hinged to a T-shaped slider. A pair of first lifting assemblies are respectively arranged at both ends of the balance beam, one end of the first lifting assembly is hinged to the corresponding first lifting point, and the other end is detachably connected to the first lifting ear of the corresponding equipment; A pair of second lifting assemblies are respectively provided at both ends of the balance beam, each comprising a lifting belt and an electric fall chain, one end of the lifting belt is connected to the corresponding second lifting point, and the other end is connected to the movable end of the electric fall chain, the fixed end of the electric fall chain is detachably connected to the corresponding third lifting point, and the lifting belt is slidably sleeved on the second lifting ear of the corresponding equipment; Center of gravity closed-loop control system, including: Two longitudinal pressure sensors are respectively arranged directly below the first hanging points at the left and right ends of the balance beam; Two lateral pressure sensors are respectively arranged on the root bearing surface of the second lifting lugs at the left and right ends of the equipment; The adaptive adjustment module integrated in the controller is configured to realize the following functions: obtaining the load value P detected by the longitudinal pressure sensor in real time 左1 With P 右1 ; Real-time acquisition of the load value P detected by the lateral pressure sensor 左2 With P 右2 ; Calculate the longitudinal load difference ΔP 纵 =|P 左1 -P 右1 |; Calculate the lateral load difference ΔP 横 =|P 左2 -P 右2 |; When ΔP 纵 >10kN and ΔP 横 When ≤5kN, control the hydraulic cylinder to extend to ΔP 纵 ≤3kN; when ΔP 横 >5kN and ΔP 纵 When ≤10kN, control the electric chain to adjust to ΔP 横 ≤2kN; when ΔP 纵 >10kN and ΔP 横 When >5kN, first control the hydraulic cylinder to move so that ΔP 纵 ≤3kN, then control the electric chain to adjust ΔP 横 ≤2kN.

[0009] Preferably, in the large equipment lifting device of the present invention, a sliding base is provided on the T-shaped slider, a main lifting lug is provided on the top of the sliding base, and the sliding base is hinged to the end of the piston rod of the hydraulic cylinder; The first lifting assembly includes a connecting plate and a pulling plate, one end of the connecting plate is hinged to the corresponding first lifting point via a first pin, the other end is hinged to one end of the pulling plate via a second pin, and the other end of the pulling plate is detachably connected to the first lifting ear of the corresponding equipment; One end of the sling is connected to the corresponding second lifting point through a first shackle, and the other end is connected to the movable end of the length-adjustable electric fall chain through a second shackle; The electric chain fall includes: a worm gear reducer, whose output shaft is connected to the sprocket; a servo motor directly connected to the reducer input shaft; and an encoder that provides real-time feedback on the sprocket rotation angle. The length L of the T-shaped guide groove must meet the following requirements: L ≥ the maximum stroke of the hydraulic cylinder + 2 × the installation length of the electric chain fall, and L ≥ 1500 mm. The lateral pressure sensor is a split structure and can be detachably mounted on the root plane of the second lifting lug through a magnetic clamp. The detection probe is in vertical contact with the bearing surface of the second lifting lug. The hydraulic drive system also includes a hydraulic pump station; The structure of the adaptive adjustment module is configured to achieve the following functions: when ΔP 纵 >10kN and ΔP 横 When ≤5kN, the adaptive adjustment module generates a hydraulic cylinder displacement instruction, driving the hydraulic pump station to make the piston rod continuously extend and retract in one direction until ΔP 纵 ≤3kN; when ΔP 横 >5kN and ΔP 纵 When ≤10kN, a chain fall adjustment instruction is generated according to the formula θ=0.65°·ΔP 横 Calculate the target rotation angle of the sprocket and drive the servo motor to make the sprocket rotation angle error ≤±0.5° until ΔP 横 ≤2kN; when ΔP 纵 >10kN and ΔP 横 When >5kN, first execute the hydraulic cylinder displacement command to make ΔP 纵 ≤3kN, then execute the chain-fall adjustment command to make ΔP 横 ≤2kN; The manual emergency mechanism of the electric chain fall includes: a manual crank interface mounted on the output shaft of the servo motor; a self-locking angle of the worm gear reducer ≤ 3°; The connection structure between the lifting belt and the second lifting ear of the equipment includes: a polyurethane wear-resistant layer with a thickness of 2-3mm lined on the lifting belt ring; and a hard alloy layer with a thickness of 0.5mm and a hardness of HRC55-60 built-up on the surface of the second lifting ear of the equipment.

[0010] Preferably, in the large equipment lifting device of the present invention, the maximum stroke of the hydraulic cylinder is 700-800 mm, and the length L of the T-shaped guide rail and the maximum stroke S of the hydraulic cylinder satisfy the following relationship: L = (1.5-1.8) × (S + 2 × L chain ), where L chain is the installation length of the electric fall chain, and L chain The value range is 150-250mm; the installation length L of the electric fall chain chain It refers to the reference installation distance from the fixed end to the movable end of the electric fall chain, measured when the electric fall chain is at its initial length.

[0011] Preferably, in the large equipment hoisting device of the present invention, the structure of the adaptive adjustment module is further configured to realize the following functions: when 8kN<ΔP 纵 ≤10kN and ΔP 横 When >4kN, do one of the following: If ΔP 横 ≤5kN, give priority to generating hydraulic cylinder displacement instructions, wait for ΔP 纵 When the load reaches ≤3kN, the chain-fall adjustment instruction will be generated; If ΔP 横 >5kN, synchronously generate hydraulic cylinder displacement command and chain fall adjustment command, and execute interlocking logic: when ΔP 纵 ≥ΔP 横 When ΔP 纵 <ΔP 横 When ΔP is reached, the displacement speed of the hydraulic cylinder takes the lower limit of 5 mm / s, and the rotation speed of the sprocket takes the upper limit of 0.8° / s; 纵 ≤3kN and ΔP 横 ≤2kN.

[0012] The present invention also provides a large equipment hoisting method, comprising the following steps: S1. Pre-assembly of the balance beam on the ground: Reposition the main lifting lug to the center of the balance beam. Connect the fixed end of the electric fall chain to the third lifting point of the balance beam via the quick-release pin assembly. Pre-enter the center of gravity coordinates of the equipment into the controller according to the center of gravity coordinates marked on the equipment drawing. S2. Connect the lifting equipment to the equipment: Operate the overhead crane hook to hook into the main lifting lug and lift the balance beam to directly above the equipment. Install the first lifting assembly: Articulate the connecting plate to the first lifting points on the left and right ends of the balance beam via the first pin. Articulate one end of the pull plate to the connecting plate via the second pin. Connect the other end of the pull plate to the first lifting lug of the equipment via a shackle. Install the second lifting assembly: Connect one end of the sling to the second lifting point of the balance beam via the first shackle. Connect the other end of the sling to the movable end of the electric fall chain via the second shackle. Slide the middle end of the sling into the second lifting lug of the equipment. S3. Preload and center of gravity calibration: Start the center of gravity closed-loop control system and monitor the longitudinal load difference ΔP in real time 纵 and the lateral load difference ΔP 横 ; When ΔP 纵 >10kN and ΔP 横 When ≤5kN, the controller drives the hydraulic cylinder to move the main lifting lug until ΔP 纵 ≤3kN; when ΔP 横 >5kN and ΔP 纵 When ≤10kN, the controller is set to θ=0.65°·ΔP 横Calculate the sprocket angle of the electric chain and drive the electric chain to adjust until ΔP 横 ≤2kN; if ΔP 纵 >10kN and ΔP 横 >5kN, first execute the hydraulic adjustment command to make ΔP 纵 ≤3kN, then execute the chain-fall adjustment command to make ΔP 横 ≤2kN; the center of gravity closed-loop control system updates ΔP every 200-500ms 纵 and ΔP 横 value, and the hydraulic cylinder displacement speed is limited to 10-15mm / s, and the sprocket rotation speed is limited to 0.8-1.2° / s; S4. Hoisting in height-restricted spaces: Lift the equipment at a speed of ≤0.5m / min. During the lifting process, maintain a clearance of ≥100mm between the bottom of the equipment and any obstacles. When the equipment is lifted to the installation height, move the overhead crane so that the deviation between the equipment axis and the foundation axis is ≤5mm. S5. Positioning and Disassembly: After the equipment is in place, remove the second shackle, release the quick-release pin assembly at the fixed end of the electric fall chain, and remove the fixed shackle and first pin at the equipment's first lifting lug. Among them, when the sling described in step S2 is inserted into the second lifting ear of the equipment, the lateral offset direction of the center of gravity is calculated according to the coordinates of the center of gravity of the equipment pre-input by the controller, and the pre-offset amount δ is set to 0.15~0.25 times the width of the equipment, and δ≤0.5×the length of the T-type guide rail groove. The offset direction is opposite to the lateral offset direction of the center of gravity of the equipment.

[0013] Preferably, in the large equipment hoisting method of the present invention, real-time posture monitoring and active collision avoidance control are added in step S4: tilt sensors are installed at the four corners of the top of the equipment to monitor the tilt angle α of the equipment in real time; laser rangefinders are installed at the four corners of the bottom of the equipment to measure the minimum distance D from the bottom of the equipment to the obstacle in real time. min ; When the following conditions are met at the same time, the collision avoidance control is automatically triggered: The equipment tilt angle α≥2° and D min ≤150mm; or D min ≤120mm; Anti-collision control includes: immediately reducing the lifting speed to ≤0.2m / min; according to formula v corr =k·α·(D min -100) calculate the horizontal correction speed of the overhead crane, where k = 0.05 (m / min) / (°·mm); drive the overhead crane to move in the direction of decreasing the inclination, and the moving speed ≤ v corr , until α<1° or D min After >200mm, the original lifting speed will be restored.

[0014] Preferably, in the large equipment hoisting method of the present invention, stress relief control is added in step S5: a tension sensor is installed at the shackle connection of the first lifting eye of the equipment to monitor the shackle axial load F in real time, and its signal output end is connected to the controller; and staged unloading is performed during the disassembly process: When removing the second shackle, if F>1.5kN, control the electric chain to slowly release the load at a speed of 0.05m / min until F≤0.8kN, then remove the shackle; When removing the fixed shackle at the first lifting eye of the equipment, drive the hydraulic cylinder to retract the piston rod 5-8mm and lock the T-type slider at the same time to generate a reverse preload force to offset the gravity of the equipment; When the tension sensor detects that the F fluctuation value is ≤±0.3kN, the fixed shackle is removed at a speed of ≤0.02m / min; After disassembly is completed, the controller activates the vibration suppression mode and controls the overhead crane to move vertically at a frequency of 0.5Hz and an amplitude of ±0.5mm for 10-15 seconds to eliminate residual stress in the equipment.

[0015] Preferably, in the large equipment hoisting method of the present invention, intelligent recovery control of the balance beam is added after step S5: magnetic quick-release connectors are integrated at the third lifting points at both ends of the balance beam, and the overhead crane auxiliary hook is equipped with an electromagnetic grabbing module; a one-key recovery protocol is executed: A1. After the device is in place, the controller sends a wireless command to activate the electromagnetic grabbing module; A2. The overhead crane's auxiliary hook moves horizontally at a speed of 0.3 m / s to the position directly above the balance beam, and the position deviation is ≤ 2 mm through laser positioning calibration. A3, magnetic quick-release connector automatically locks within a distance of 10-15cm, with an adsorption force of ≥8kN; A4. Synchronous release of the main hook and auxiliary hook loads: The main hook descends at a speed of 0.4m / min; the auxiliary hook ascends at a speed of 0.35m / min. Weight sensors installed on the main and auxiliary hooks monitor the load transfer rate in real time. When the load ratio of the main and auxiliary hooks reaches 1:9, the main hook is fully released. A5. The auxiliary hook lifts the balance beam to the recovery frame, and the magnetic joint is automatically demagnetized and released after contacting the safety limiter.

[0016] Preferably, in the large equipment hoisting method of the present invention, dynamic balance compensation is added during the load transfer process in step A4: a three-axis gyroscope is integrated inside the balance beam to monitor the beam's pitch angle γ and roll angle β in real time; when |γ| ≥ 1.0° or |β| ≥ 1.2°, the following synchronous compensation is performed: Start the hydraulic drive system and press the formula ΔL x =K·β·L b Calculate the lateral compensation, where K=0.15, L b is the balance beam length; Control the differential extension and contraction of the left and right hydraulic cylinders: left cylinder displacement + ΔL x / 2, right cylinder displacement -ΔL x / 2; At the same time, adjust the horizontal deviation correction speed of the overhead crane anti-collision system so that v corr An additional increment of Δv = 0.02·|γ| m / min was added until |γ| ≤ 0.1° and |β| ≤ 0.2°, and then the original load transfer speed was restored.

[0017] Preferably, in the large equipment hoisting method of the present invention, a visually assisted positioning system is synchronously activated during dynamic balance compensation: wide-angle industrial cameras are installed at both ends of the balance beam to capture the position deviation between the second lifting lug of the equipment and the second lifting point of the balance beam in real time; When the image recognition shows that the lateral offset of the second lifting eye is ≥3mm during the differential extension and contraction of the hydraulic cylinder or the deviation correction of the overhead crane, or the laser rangefinder detects that the change rate of the distance between the equipment and the obstacle is greater than 5mm / s, the system automatically generates a dynamic compensation correction factor; The correction factors include: adding 0.2 times the visual offset to the hydraulic differential; increasing the overhead crane's correction speed to 1.3 times its value; Compensation continues until the image deviation is ≤0.5mm and the distance change rate is ≤1mm / s, and the real-time positioning enhanced view is superimposed on the controller interface.

[0018] The present invention has at least the following beneficial effects: 1. Real-time feedback of load distribution is obtained through the longitudinal pressure sensor (below the first lifting point) and the transverse pressure sensor (at the base of the equipment lifting lug), and the longitudinal imbalance is adjusted by the hydraulic cylinder (converging to ΔP 纵 ≤3kN), electric chain-fall adjustment for lateral imbalance (convergence to ΔP 横 ≤2kN), achieving fully automatic, high-precision posture correction. The closed-loop control response cycle is ≤500ms, reducing manual adjustment time by over 90% and eliminating the risk of equipment tipping due to center of gravity shift.

[0019] The manual crank interface is directly connected to the servo motor output shaft, enabling manual mode within 10 seconds after a power outage. The worm gear self-locking angle is ≤3°, ensuring load stability. The sling's polyurethane wear-resistant layer (2-3mm) and the lifting lug's carbide coating (HRC55-60) reduce the coefficient of friction to below 0.25, extending the sling's lifespan to 1,000 cycles and reducing replacement costs.

[0020] 3. Guide rail groove length formula L =(1.5~1.8)×( S +2× L chainPrecisely matching the hydraulic cylinder stroke (700-800mm) and the fall chain installation length (150-250mm) eliminates the risk of actuator interference. A safety factor of 1.5-1.8 covers dynamic impact conditions, and the ineffective length of the guide rail groove is reduced by 30%, improving material utilization.

[0021] 4. For critical state (8kN<ΔP 纵 ≤10kN and ΔP 横 >4kN), press ΔP 横 If the value is >5kN, branch processing: if the value is within the limit, hydraulic adjustment is given priority; if the value is exceeded, synchronous adjustment is made based on ΔP. 纵 / ΔP 横 Dynamically distribute speeds (hydraulic 5-10 mm / s, sprocket 0.5-0.8° / s). Interlocking logic reduces compound imbalance adjustment time by 40%, preventing power conflicts from causing system oscillations.

[0022] 5. A pre-set offset of δ = 0.15-0.25 times the equipment width actively offsets center of gravity shift, reducing hydraulic cylinder stroke by over 30%. A lifting speed of ≤ 0.5 m / min and a 100 mm clearance threshold ensure safety in confined spaces. The disassembly sequence is to remove the fall chain first, then the sling, and finally the rigid connection, reducing the risk of sudden stress changes by 80%. Pre-entering the center of gravity coordinates increases sling positioning efficiency by 50%.

[0023] 6. Double trigger conditions (inclination angle α ≥ 2° and D min ≤150mm or D min ≤120mm) covers 98% of collision risk scenarios. Correction formula v corr =0.05× α ×( D min -100) dynamically associates posture and distance, reducing the lifting speed to 0.2m / min to reserve 3 seconds for manual intervention, reducing the probability of collision in narrow spaces to less than 1%.

[0024] 7. Gradual Unloading Control: Before removing the fall chain, the load is released to ≤0.8kN (threshold 1.5kN). When removing the shackle, the hydraulic cylinder retracts ΔL=0.6√Wmm to offset gravity, and after F fluctuations ≤±0.3kN, the device is disassembled at a slow speed. The impact load is reduced to within 1.2 times the static load, and a 0.5Hz vertical micro-motion is used to eliminate stress in the anchor bolt assembly, achieving a positioning accuracy of ±0.5mm.

[0025] Magnetic couplings automatically attach (≥8kN) within a 10-15cm range, with laser positioning deviations ≤2mm, eliminating manual hooking. The speed differential between the primary and secondary hooks (0.4m / min down, vs. 0.35m / min up) maintains wire rope tension, and a 1:9 load transfer ratio ensures stable retrieval of the balance beam, reducing overhead work time by 95%.

[0026] 9. The three-axis gyroscope (accuracy ±0.05°) monitors the pitch angle γ and roll angle β in real time. When |γ| ≥ 1.0° or |β| ≥ 1.2°, the hydraulic differential compensation ΔL x =0.15×β×L b To counteract the rolling moment, the correction speed increment Δv = 0.02 × |γ| m / min is used to suppress pitch. The attitude converges to |γ| ≤ 0.1° and |β| ≤ 0.2°, and the risk of capsizing approaches zero.

[0027] 10. The vision system triggers compensation when image deviation ≥ 3mm or distance change rate > 5mm / s: the hydraulic system adds 0.2 times the visual offset, increasing correction speed by 1.3 times. FPGA processing latency ≤ 50ms ensures real-time performance, converging to image deviation ≤ 0.5mm and distance change rate ≤ 1mm / s, with 100% mechanical lag compensation.

[0028] Other advantages, objectives and features of the present invention will be reflected in part from the following description and will be understood by those skilled in the art through study and practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 This is a right side structural diagram of a large equipment lifting device in one of the technical solutions of the present invention; Figure 2 This is a schematic diagram of the main structure of a large equipment lifting device in one of the technical solutions of the present invention; Figure 3 It is a right-side structural schematic diagram of a large equipment lifting device and equipment assembly in one of the technical solutions of the present invention; Figure 4 This is a schematic diagram of the main structure of a large equipment lifting device and equipment assembly in one of the technical solutions of the present invention; Among them, 1-main lifting eye, 2-balance beam, 3-electric fall chain, 4-sling, 5-second lifting eye, 6-first lifting eye, 7-pull plate, 8-connecting plate. DETAILED DESCRIPTION

[0030] The present invention will be described in further detail below in conjunction with the accompanying drawings so that those skilled in the art can implement the invention with reference to the description.

[0031] It should be understood that terms such as “having”, “including” and “comprising” used herein do not preclude the existence or addition of one or more other elements or combinations thereof.

[0032] According to one embodiment of the present invention, a large-scale equipment lifting device is provided. A T-shaped guide groove runs along the top surface of a balance beam (2). A T-shaped slider slides within the groove. A sliding base is fixed to the top of the T-shaped slider, and a main lifting lug (1) is mounted on the sliding base. First, second, and third lifting points are symmetrically positioned at each end of the balance beam. A hydraulic drive system is integrated within the balance beam. The hydraulic cylinder body is fixed within the balance beam, and the piston rod end is hingedly connected to the sliding base. A hydraulic pump station provides power, and a controller coordinates the operation.

[0033] The first lifting assembly consists of a connecting plate 8 and a pull plate 7. One end of the connecting plate is hinged to the first lifting point of the balance beam via a first pin, and the other end is hinged to the pull plate via a second pin. The other end of the pull plate is connected to the first lifting eye 6 of the equipment via a shackle. The second lifting assembly consists of a sling 4 and an electric fall chain 3. One end of the sling is connected to the second lifting point of the balance beam via a first shackle, and the other end is connected to the movable end of the electric fall chain via a second shackle. The fixed end of the electric fall chain is connected to the third lifting point. The middle portion of the sling slides over the second lifting eye 5 of the equipment. The electric fall chain incorporates a built-in worm gear reducer, servo motor, and encoder, which provides real-time feedback on the sprocket rotation angle.

[0034] The center of gravity closed-loop control system includes: Two longitudinal pressure sensors are located directly below the first hanging point on the left and right ends of the balance beam to measure the load value P 左1 With P 右1 ; Two lateral pressure sensors are detachably mounted on the bearing surface of the left and right second lifting lugs of the equipment through magnetic clamps. The detection probes are in vertical contact with the bearing surface to measure the load value P. 左2 With P 右2 .

[0035] The adaptive adjustment module in the controller performs the following logic: 1. Calculate the longitudinal load difference ΔP 纵 =|P 左1 -P 右1 |, lateral load difference ΔP 横 =|P 左2 -P 右2 |; 2. If ΔP 纵 >10kN and ΔP 横 ≤5kN, drive the hydraulic cylinder to extend and retract the piston rod until ΔP 纵 ≤3kN; 3. If ΔP 横 >5kN and ΔP 纵 ≤10kN, according to θ=0.65°·ΔP 横 Calculate the target rotation angle of the sprocket and drive the servo motor to make the rotation angle error ≤±0.5° until ΔP 横 ≤2kN; 4. If ΔP 纵 >10kN and ΔP 横 >5kN, first perform hydraulic adjustment to ΔP 纵 ≤3kN, then adjust the chain to ΔP 横 ≤2kN.

[0036] The calculation formula of θ is based on the following: the coefficient 0.65° is determined by the mechanical transmission characteristics of the electric chain hoist, specifically the worm gear reducer reduction ratio i=40:1, the sprocket pitch circle diameter d=120mm, and the sling displacement formula Δs=(θ / 360°)×πd and the arm balance equation ΔP 横 × arm length = k·Δs, θ and ΔP are derived 横 The linear proportional coefficient meets the requirement that the sling displacement corresponds to 3.5mm for every 1kN load difference; the length L of the T-guide groove must meet the following requirements: L ≥ maximum stroke of the hydraulic cylinder + 2 × installation length of the electric fall chain (L ≥ 1500mm) to ensure that the sliding range of the main lifting eye covers the adjustment requirements.

[0037] Extended function of the tension sensor: A tension sensor is added to the shackle connection of the first lifting eye 6 of the equipment. The real-time monitored axial load F signal is transmitted to the controller for stress relief control in the subsequent disassembly stage.

[0038] Traditional large-scale equipment hoisting devices typically utilize a fixed balance beam structure, and the lifting point position cannot be adjusted. If the equipment's center of gravity shifts during the hoisting process, manual adjustments to the sling length or the movement of the overhead crane are required, which is inefficient and poses a safety hazard. In existing technologies, pressure sensors are often mounted on the hook or wire rope, making it impossible to directly monitor the load-bearing stress at the base of the equipment's lifting lugs. This results in a deviation between the feedback data and the actual load status. Furthermore, the hydraulic cylinder and chain-falling system operate independently, lacking coordinated control logic, making it prone to system oscillations due to response delays.

[0039] In this embodiment, the coordinated layout of longitudinal and transverse pressure sensors is used to directly detect the stress at the root of the equipment lifting lug, eliminating the error of traditional indirect measurement; the hierarchical control strategy of the hydraulic cylinder and the electric fall chain (longitudinal priority, transverse second) avoids two-way adjustment conflicts and improves system stability; the longitudinal load difference is automatically converged to within 3kN and the transverse load difference is converged to within 2kN to ensure the balance of the equipment lifting posture; the transverse pressure sensor installed with a magnetic clamp can be quickly disassembled and assembled to adapt to different equipment lifting lug structures.

[0040] According to another embodiment of the present invention, a large equipment hoisting device features a manual emergency mechanism for an electric chain fall, including a manual crank interface mounted on the servo motor output shaft. In the event of a power outage, the operator inserts the manual crank into the interface, directly rotating the servo motor output shaft. The worm gear reducer's self-locking angle is designed to be no greater than 3 degrees, ensuring that when manual operation ceases, the worm gear mechanism instantly self-locks the load, preventing the equipment from accidentally falling.

[0041] The connection structure between the lifting strap and the second lifting lug of the equipment includes two improvements: 1. The inner lining of the sling collar can be provided with a polyurethane wear-resistant layer with a thickness of 2 mm to 3 mm. The Shore hardness (ASTM D2240 standard) of this material is 85A-90A and the friction coefficient is ≤0.25, which reduces the wear rate of the contact surface with the lifting lug; 2. The surface of the second lifting lug of the equipment can be surfacing welded with a 0.5 mm thick cemented carbide layer with a Rockwell hardness of HRC55 to HRC60 and a surface roughness of Ra≤1.6μm to form a wear-resistant hardened surface.

[0042] Among them, the self-locking angle is ≤3°. According to the calculation formula of the worm gear friction angle μ=tanρ (ρ is the friction angle), when μ=0.05, ρ=2.86°. This design takes γ=2.8°. When the worm lead angle γ≤ρ, self-locking is achieved; the thickness of the polyurethane layer is 2-3mm. It was determined by wear test: the wear depth of the sling is ≤0.1mm after 500 sliding times under a load of 10 tons.

[0043] Traditional electric fall chains require complete disassembly to activate manual mode in the event of a power outage or malfunction, a time-consuming and risky operation at height. Direct friction between the lifting straps and the equipment's lifting lugs can easily cause wear, especially when lifting heavy equipment. Typical nylon straps have a lifespan of less than 200 cycles. Existing manual emergency mechanisms often utilize a detachable handle, which lacks the reliability of the worm gear's self-locking mechanism and poses the risk of load slippage.

[0044] In this embodiment, the manual crank interface is directly connected to the motor output shaft, achieving emergency switching within 10 seconds without removing the chain housing; the self-locking angle ≤ 3° ensures that the load displacement does not exceed 1 mm when manual operation is terminated; the polyurethane wear-resistant layer increases the life of the sling to more than 1,000 cycles; the carbide layer reduces the wear rate of the lifting ear to 1 / 5 of the untreated surface.

[0045] According to another embodiment of the present invention, a large equipment lifting device is provided, wherein the maximum stroke of the hydraulic cylinder is set to a range of 700 mm to 800 mm. The length L of the T-shaped guide rail groove is determined by the following formula: L =(1.5~1.8)×( S +2× L chain ),in, SIndicates the maximum stroke of the hydraulic cylinder (700-800mm); L chain Indicates the installation length of the electric fall chain, ranging from 150 mm to 250 mm.

[0046] Electric fall chain installation length L chain Defined as the straight-line distance from the fixed end (connected to the third lifting point of the balance beam) to the movable end (connected to the second shackle of the sling) of the electric fall chain at its initial length. This length is factory-calibrated and requires actual measurement and verification during installation.

[0047] Among them, the coefficients 1.5 to 1.8 cover the safety margin: 1.5 times corresponds to static load conditions, 1.8 times covers dynamic impact conditions; 2× L chain Ensure that when the hydraulic cylinder is extended or retracted, the distance between the two ends of the fall chain and the end of the guide rail groove is at least 0.25× L chain Clearance to avoid mechanical interference.

[0048] In traditional lifting systems, the hydraulic cylinder stroke and guideway length are often designed independently, without considering the space requirements for the electric fall chain. When the hydraulic cylinder is extended to its limit, insufficient clearance between the movable and fixed ends of the fall chain can cause the sling to twist or the fall chain housing to collide. Existing guideway lengths are often determined empirically, lacking a quantitative formula to correlate with hydraulic stroke, which can lead to structural redundancy and interference risks.

[0049] In this embodiment, the hydraulic cylinder stroke, the chain size and the guide rail groove length are related by quantitative formula to eliminate the collision risk of moving parts; L chain The range covers mainstream chain-fall models and is suitable for equipment of different tonnages; the guide rail groove length precisely matches the actuator requirements, reducing the ineffective weight of the balance beam and improving material utilization.

[0050] According to another embodiment of the present invention, a large equipment lifting device is provided, wherein the adaptive adjustment module extends the following control logic: when a longitudinal load difference ΔP is detected 纵 Greater than 8 kN but not exceeding 10 kN, and the lateral load difference ΔP 横 When the speed exceeds 4 kN, the branch strategy is executed: 1. If ΔP 横 No more than 5 kN, first generate the hydraulic cylinder displacement command to drive the piston rod to extend and retract, wait for ΔP 纵 After converging to within 3 kN, a chain-falling adjustment instruction is generated to adjust the sprocket angle; 2. If ΔP 横 When the load exceeds 5 kN, the hydraulic cylinder displacement command and the chain fall adjustment command are generated synchronously, and the interlocking logic is activated: When ΔP 纵 The value is greater than or equal to ΔP 横 When ΔP is set, the displacement speed of the hydraulic cylinder is set to the upper limit of 10 mm per second, and the rotation speed of the sprocket is set to the lower limit of 0.5 degrees per second; 纵 The value is less than ΔP 横 When setting the hydraulic cylinder displacement speed to the lower limit of 5 mm per second, the sprocket rotation speed is set to the upper limit of 0.8 degrees per second; 3. Continue to adjust until ΔP is satisfied at the same time 纵 Not exceeding 3 kN and ΔP 横 Not exceeding 2 kilonewtons.

[0051] The speed thresholds of 10 mm / s and 5 mm / s are calculated based on the maximum flow rate (20 L / min) and cylinder diameter (80 mm) of the hydraulic cylinder to ensure that the pressure fluctuation is ≤ 15% of the rated value. The sprocket speeds of 0.5° / s and 0.8° / s correspond to the servo motor speed range (30-48 rpm) to avoid overshoot vibration.

[0052] Conventional hoisting systems typically employ sequential execution or fixed speed control strategies when both longitudinal and lateral load differences approach set thresholds. For example, when the longitudinal load difference is slightly above the threshold while the lateral load difference significantly exceeds the standard, longitudinal priority is still applied, leading to continued worsening of lateral imbalance. Existing control systems lack a dynamic speed adaptation mechanism for complex critical conditions, resulting in low control efficiency.

[0053] In this embodiment, for the critical unbalance state (8kN<ΔP 纵 ≤10kN and ΔP 横 >4kN) to achieve refined hierarchical control and reduce adjustment time; interlocking logic is based on ΔP 纵 With ΔP 横 The ratio of 200 to 300 is used to dynamically distribute the actuator speed to avoid power conflicts between the hydraulic system and the chain-falling system; the upper and lower speed limits (5-10 mm / s for hydraulic cylinders and 0.5-0.8° / s for sprockets) ensure the stability of the system under complex adjustment conditions.

[0054] According to another embodiment of the present invention, a method for hoisting large equipment is provided, comprising the following steps: Step S1: Balance beam ground pre-assembly Move the main lifting eye 1 to the center position of the balance beam 2 and lock it; connect the fixed end of the electric fall chain 3 to the third lifting point of the balance beam through the quick-release pin shaft assembly; pre-input the center of gravity position data into the controller according to the three-dimensional coordinates of the center of gravity marked on the equipment drawing.

[0055] Step S2: Connecting the spreader to the equipment Operate the main hook of the overhead crane to hook into the main lifting lug 1, and lift the balance beam 2 to the top of the equipment; Install the first lifting assembly: the connecting plate 8 is hinged to the first lifting points on the left and right ends of the balance beam through the first pin, one end of the pull plate 7 is hinged to the connecting plate 8 through the second pin, and the other end of the pull plate 7 is connected to the first lifting ear 6 of the equipment through a shackle; Install the second lifting assembly: one end of the lifting belt 4 is connected to the second lifting point of the balance beam through the first shackle, and the other end is connected to the movable end of the electric fall chain 3 through the second shackle. The middle part of the lifting belt 4 is slidably inserted into the second lifting eye 5 of the equipment; Pre-offset setting: Calculate the lateral offset direction of the center of gravity based on the pre-input center of gravity coordinates, and set the pre-offset amount δ of the sling 4 on the second lifting eye 5 to 0.15~0.25 times the equipment width. The offset direction is opposite to the lateral offset direction of the center of gravity (for example, if the center of gravity shifts to the left, the sling shifts to the right).

[0056] Step S3: Preload and center of gravity calibration Start the center of gravity closed-loop control system and monitor the longitudinal load difference ΔP in real time 纵 and the lateral load difference ΔP 横 , update cycle 200-500 milliseconds; When ΔP 纵 >10kN and ΔP 横 When ≤5kN, the controller drives the hydraulic cylinder to move the main lifting eye 1 until ΔP 纵 ≤3kN; When ΔP 横 >5kN and ΔP 纵 When ≤10kN, according to the formula θ=0.65°·ΔP 横 Calculate the sprocket angle and drive the electric chain breaker 3 to adjust to ΔP 横 ≤2kN; When ΔP 纵 >10kN and ΔP 横 When >5kN, first adjust the hydraulic pressure to ΔP 纵 ≤3kN, then adjust the chain to ΔP 横 ≤2kN; Speed ​​constraints: hydraulic cylinder displacement speed 10-15 mm per second, sprocket rotation speed 0.8-1.2 degrees per second.

[0057] Step S4: Hoisting in a height-restricted space Lift the equipment at a speed not exceeding 0.5 m / min; maintain a minimum clearance of ≥100 mm between the bottom surface of the equipment and obstacles in real time; after the equipment is lifted to the installation height, move the overhead crane so that the deviation between the equipment axis and the foundation axis is ≤5 mm.

[0058] Step S5: Positioning and disassembly After the equipment is in place, remove the second shackle (the connection point between the sling 4 and the fall chain 3), release the quick-release pin assembly at the fixed end of the electric fall chain 3, and remove the fixed shackle at the first lifting ear 6 of the equipment and the first pin (the hinge point between the connecting plate 8 and the balance beam).

[0059] Among them, the pre-offset δ = 0.15~0.25 times the equipment width, and δ ≤ 0.5 × T-guide groove length: after testing, it can offset more than 80% of the natural tilt torque of the equipment; the lifting speed ≤ 0.5m / min: ensure that the laser rangefinder (if installed) has a response time adjustment gap of ≥ 300ms; the axis deviation ≤ 5mm: meet the tolerance requirements of the equipment foundation bolt hole diameter.

[0060] In traditional large-scale equipment lifting methods, the sling installation position is often determined empirically, without considering pre-shift compensation for the equipment's center of gravity. When lifting in height-constrained spaces, operators must constantly visually check the clearance between the equipment's bottom and obstacles, which can easily lead to collisions due to visual errors. Existing center of gravity calibration relies on multiple trial lifts, which is inefficient and lacks quantitative standards for hydraulic cylinder and fall chain adjustment parameters.

[0061] In this implementation, the pre-offset δ actively compensates for center-of-gravity shift, reducing the hydraulic cylinder stroke during the calibration phase by approximately 40%. A lifting speed of 0.5 m / min combined with a 100 mm clearance threshold prevents collisions in confined spaces. A 200-500 millisecond monitoring cycle matches the actuator response speed, eliminating adjustment lag. The disassembly sequence (first the fall chain, then the sling, and finally the rigid connection) reduces the risk of residual stress release.

[0062] According to another embodiment of the present invention, a method for hoisting large equipment is provided, wherein during the lifting process in step S4, the following extended operations are performed: 1. Sensor layout includes: installing tilt sensors at the four corners of the top of the equipment to monitor the equipment's tilt angle α (unit: degree) in real time; installing laser rangefinders at the four corners of the bottom of the equipment to measure the minimum distance D from the bottom of the equipment to obstacles in real time. min (Unit: mm).

[0063] 2. Anti-collision trigger conditions (if any one of them is met, it will be triggered): a) The device tilt angle α ≥ 2 degrees and D min ≤150 mm; b)D min ≤120 mm.

[0064] 3. Anti-collision control actions include: immediately reducing the lifting speed to no more than 0.2 meters per minute; according to the formula v corr =0.05× α ×( D min -100) calculate the horizontal deviation correction speed of the overhead crane (unit: meters per minute); drive the overhead crane to move in the direction of decreasing inclination (for example, move to the right if it is tilted to the left), and the moving speed shall not exceed v corr ; Continue to correct until α<1 degree or D min >200mm, then resume original lifting speed.

[0065] The coefficient of 0.05 was determined through dynamic simulation: when the mass of the overhead crane is 10 tons and the mass of the equipment is 50 tons, this coefficient can make the correction acceleration ≤ 0.01g; the threshold of 120mm corresponds to the braking distance of the laser rangefinder at a speed of 0.2m / min (the response delay of the lifting system is 200ms).

[0066] Traditional lifting processes rely on manual observation of equipment tilt, making it impossible to quantify posture deviations in real time. When lifting equipment in confined spaces, operators must simultaneously monitor both height and horizontal position, which can lead to distracted attention and collisions with obstacles. Existing anti-collision measures often rely on a single speed limit, without a coordinated control model that considers tilt angle and obstacle distance.

[0067] In this implementation, the dual-condition trigger mechanism (tilt + distance or pure distance) covers more comprehensive risk scenarios; the correction speed v corr With the inclination angle α and gap D min Dynamic association to avoid over-adjustment or under-adjustment; the lifting speed is reduced to 0.2m / min to reserve at least 3 seconds of reaction time for manual intervention; exit conditions (α<1° or D min >200mm) Ensure that the equipment has returned to a safe position before continuing operations.

[0068] According to another embodiment of the present invention, a method for hoisting large equipment is provided, wherein the following operations are added during the disassembly process in step S5: 1. Tension sensor installation: Install a tension sensor at the shackle connection of the first lifting eye 6 of the equipment. It monitors the shackle axial load F (unit: kN) in real time and transmits the signal to the controller. 2. Gradual unloading process: When removing the second shackle, if F>1.5kN, control the electric fall chain 3 to slowly release the load at a speed of 0.05m / min until F≤0.8kN, then remove the shackle; When removing the fixed shackle from the first lifting eye 6 of the equipment, a) drive the hydraulic cylinder to retract the piston rod by 5mm to 8mm; b) simultaneously lock the T-shaped slide block to generate a reverse preload force to offset the weight of the equipment; c) when the tension sensor detects that the F fluctuation value is ≤±0.3kN, remove the fixed shackle at a speed of ≤0.02m / min; 3. Vibration suppression mode: After disassembly, the controller activates vibration suppression: the overhead crane is controlled to move vertically at a frequency of 0.5 Hz and an amplitude of ±0.5 mm for 10 to 15 seconds. Among them, the piston rod retraction amount ΔL is calculated according to the equipment weight W (unit: tons) according to the formula Δ L =0.6×√ WCalculated in millimeters. For example, the retraction of a 70-ton machine is ΔL = 0.6 × √70 ≈ 5.02 mm (within the range of 5-8 mm). Finite element analysis shows that this retraction can release the stress of the lifting lug to a safe threshold (≤ 30% of the material yield strength). Traditional equipment removal involves directly releasing the shackles during lifting. This sudden release of load can easily lead to equipment displacement or structural damage. Especially when the weight of the equipment has not been fully transferred to the foundation, the impact load generated by the shackle removal can reach more than three times the original load. Existing methods lack a mechanism for quantitatively monitoring residual stress and grading its release.

[0069] In this implementation, graded unloading reduces the disassembly impact load to within 1.2 times the original load. The piston rod retracts 5-8mm and the T-slider locks, offsetting more than 90% of the equipment's gravity transmitted to the shackle. 0.5Hz vertical micro-motion eliminates assembly stress between the equipment foundation and the anchor bolts. The F fluctuation value of ≤±0.3kN ensures that the system is in static equilibrium during disassembly. According to another embodiment of the present invention, a method for lifting large equipment is provided, and the hardware configuration is as follows: magnetic quick-release connectors are integrated at the third lifting points at both ends of the balance beam; an electromagnetic grabbing module is installed on the auxiliary hook of the overhead traveling crane, which can receive wireless command activation.

[0070] One-click recycling agreement process: a) After the device is in place, the controller sends a wireless command to activate the electromagnetic grabbing module; b) The overhead crane's auxiliary hook moves horizontally at a speed of 0.3 m / s to the position directly above the balance beam, and laser positioning calibration is used to ensure that the position deviation does not exceed 2 mm; c) The magnetic quick-release connector automatically locks within a distance of 10cm to 15cm, with an adsorption force of no less than 8kN; d) Synchronous release of the main and auxiliary hook loads: the main hook descends at a speed of 0.4m / min; the auxiliary hook ascends at a speed of 0.35m / min; the weight sensors integrated in the main and auxiliary hook lifting rings monitor the load in real time. When the main and auxiliary hook load ratio reaches 1:9, the main hook is fully released; e) The auxiliary hook hoists the balance beam to the recovery frame. The magnetic joint contacts the safety limiter and automatically demagnetizes and releases. Simultaneously, the auxiliary hook rises 50 mm at a speed of 0.1 m / s, ensuring that the balance beam is isolated from the recovery frame before release.

[0071] The weight sensors are integrated into the lifting rings of the main and auxiliary hooks of the overhead crane and utilize a strain gauge full-bridge circuit with a measurement error of ≤±0.5%FS. The suction force design must meet the following requirements: suction force ≥ k·G (G is the actual deadweight of the balance beam, k = 2.0). When G = 3.8t, the suction force is ≥ 2.0 × 3.8 × 9.8 ≈ 74.5kN, allowing a maximum suction force of 75kN.

[0072] Traditional balance beam recovery requires operators to climb equipment to dismantle the sling, a risky and time-consuming process. The overhead crane's auxiliary hook lacks a dedicated docking mechanism, and manual hooking success rates are less than 70%. The load transfer process relies on empirical judgment, making it prone to overturning the balance beam due to unsynchronized unloading of the main and auxiliary hooks.

[0073] In this embodiment, the magnetic joint automatically attracts at a distance of 10-15cm, eliminating the manual hooking link; the 1:9 load transfer ratio ensures a stable transition of the balance beam's center of gravity to the auxiliary hook; the 0.4m / min and 0.35m / min speed difference design keeps the wire rope in a tensioned state; the safety limiter triggers demagnetization to prevent the balance beam from hitting the recovery frame.

[0074] According to another embodiment of the present invention, a method for hoisting large equipment is provided, wherein dynamic balance compensation is added during the load transfer process in step d: 1. Three-axis gyroscope integration: A three-axis gyroscope is installed inside the balance beam to monitor the beam's pitch angle γ and roll angle β in real time.

[0075] 2. Imbalance determination conditions: When the absolute value of γ is greater than or equal to 1.0°, or the absolute value of β is greater than or equal to 1.2°, the compensation mechanism is triggered.

[0076] 3. Synchronous compensation action: a) Hydraulic differential adjustment: According to the formula Δ L x =0.15× β × L b Calculate the lateral compensation (unit: mm), where L b is the length of the balance beam (unit: mm), 0.15 is the compensation coefficient; controls the differential extension and retraction of the left and right hydraulic cylinders, and the extension of the left hydraulic cylinder is Δ L x / 2, the right hydraulic cylinder shortens Δ L x / 2.

[0077] b) Enhanced crane deviation correction: The horizontal deviation correction speed of the crane anti-collision system (composed of an inclination sensor and a laser rangefinder) is enhanced. v corr Additional increment Δ v =0.02×| γ ∣ (unit: meters per minute); 4. Continue compensation until the absolute value of γ does not exceed 0.1° and the absolute value of β does not exceed 0.2°, then restore the original load transfer speed.

[0078] The three-axis gyroscope has an accuracy of ±0.05°, a sampling frequency of no less than 100Hz, and a drift error of ≤0.010.01° / h maintained by the internal temperature control module of the balance beam. Zero point calibration is required before each operation: Place the balance beam horizontally on the ground and press and hold the calibration button for 3 seconds to reset the angle reference. The compensation coefficient of 0.15 is based on the principle of moment balance: when the roll angle is β, the overturning moment M=G·L β ·sinβ (G is the weight of the balance beam), the restoring torque generated by the hydraulic cylinder thrust difference ΔF must satisfy ΔF·L β =M. Combined with the typical parameters of this device (G=4t, F max =100kN), iterative calculations determined that K = 0.15 can cover 90% of the working conditions. ANSYS transient dynamics simulation, when β = 5°, L β =3m, G=8t: Actual compensation required ΔL x =38mm, calculate ΔL according to the formula x =0.15×5×3000=225mm, hydraulic cylinder thrust difference ΔF=225mm / 1500mm×100kN=15kN <F max (100kN), proving that the formula fully covers extreme working conditions. When calculating the compensation ΔL x When the hydraulic cylinder maximum stroke S is less than or equal to 0.7, the hydraulic differential extension is executed; otherwise, the overhead crane deviation correction increment Δv is triggered first, until ΔL x ≤0.7S.

[0079] Traditional load transfer processes only monitor changes in the weight of the main and auxiliary hooks, without real-time monitoring of the balance beam's spatial posture. If the main hook releases too quickly or the auxiliary hook lifts unevenly, the balance beam can easily pitch or roll, potentially causing the hoist to collide with equipment. Existing correction methods rely on manual adjustments by the overhead crane operator, resulting in a response delay exceeding three seconds.

[0080] In this embodiment, the hydraulic differential compensation (left cylinder + Δ L x / 2, right cylinder -Δ L x / 2) directly offsets the rolling moment; the correction speed increment Δv = 0.02×|γ|m / min suppresses the pitch trend and prevents the beam from swinging; the convergence thresholds of 0.1° and 0.2° ensure that the load transfer continues after the posture is stabilized; the 100 Hz sampling frequency matches the hydraulic system response bandwidth (10-15 Hz).

[0081] According to another embodiment of the present invention, a method for hoisting large equipment is provided, wherein a visually assisted positioning system is synchronously activated during a dynamic balance compensation process: 1. Hardware configuration: Wide-angle industrial cameras are installed at both ends of the balance beam, with a focal length range of 2.8mm-4mm and a field of view of ≥120°. The cameras capture images of the position deviation between the second lifting lug 5 of the equipment and the second lifting point of the balance beam in real time.

[0082] 2. Anomaly detection conditions (if any one of them is met, correction will be triggered): a) Image recognition shows that the lateral offset of the second lifting lug 5 is ≥ 3 mm; b) The laser rangefinder detects that the distance change rate between the device and the obstacle is greater than 5mm / s.

[0083] 3. Correction factor generation: Hydraulic differential force ΔL x Additional compensation: additional amount = 0.2 × visual detection offset (unit: mm); Increase the overhead crane's deviation correction speed to 1.3 times the original value: v corrnew =1.3×v corr ; 4. Continue compensation until the image recognition deviation is ≤0.5mm and the distance change rate is ≤1mm / s; 5. The controller interface overlays and displays a real-time positioning enhanced view, including the second lifting lug 5 contour recognition frame and the deviation vector line.

[0084] Image processing utilizes an FPGA (Field Programmable Gate Array) acceleration chip (Xilinx Artix-7) with a built-in parallel pipeline architecture, resulting in a delay of ≤50ms from image acquisition to deviation calculation output. This built-in parallel pipeline architecture allows for a frame processing cycle of ≤8ms (at 30 frames per second), ensuring real-time dynamic compensation. The coefficient of 0.2 was determined through 23 collision tests: when the mechanical gap is 0.2±0.05mm, the compensation amount is 0.2×δ. vis 98.7% of interference risks can be avoided; the speed coefficient of 1.3 is the braking safety margin, meeting the requirement of Δt response ≤ 0.1s.

[0085] Traditional dynamic balancing compensation relies on a single attitude sensor, making it impossible to verify the actual position offset of the external equipment's lifting lugs in real time. Mechanical lag during differential extension and retraction of hydraulic cylinders or during overhead crane correction can lead to unexpected contact with obstacles. Existing systems lack a mechanism to integrate visual feedback with internal sensor data for verification.

[0086] In this implementation, a visual offset threshold of ≥3mm prevents false triggering due to minor jitters; a 0.2x visual offset supplement compensates for mechanical transmission backlash (the measured average backlash is 0.15-0.25mm); a 1.3x correction speed boost suppresses emergency conditions where the distance change rate is >5mm / s; a ≤50ms processing delay matches the hydraulic system response time (40-60ms); and a real-time positioning enhanced view assists the operator in verifying the automatic compensation results.

[0087] Example: Steam turbine rotor hoisting into place Application scenarios: The high-pressure rotor of a 300MW unit at a power plant needed to be replaced. The rotor weighed 82 tons, was 12.3 meters long, and had a center of gravity offset by 1.2 meters from the axial center. The installation location was restricted by a height-restricted piping layer (with only 350mm clearance), and the bottom foundation bolt holes had a tolerance of ±3mm.

[0088] Device implementation: 1. Balance beam pre-assembly A 100-ton load-bearing balance beam is selected, with a T-type guide rail length of L = 2200mm (hydraulic cylinder stroke S = 750mm, electric fall chain installation length L chain =200mm, calculated as L=1.7×(750+2×200)). Move the main lifting lug 1 to the center of the beam and lock it. Connect the fixed end of the electric fall chain 3 to the third lifting point.

[0089] 2. Installation of sling The main hook of the overhead crane lifts the balance beam to the top of the rotor; First lifting assembly: The connecting plate 8 is hinged to the left / right first lifting point of the balance beam through a pin, and the other end of the pull plate 7 is connected to the forged lifting lug 6 (diameter 200mm) on the rotor journal; Second lifting assembly: The lifting belt 4 is inserted into the rotor cylinder lifting ear 5. According to the pre-input center of gravity coordinates (to the right of the offset direction), the lifting belt pre-offset δ=0.2×rotor width=0.2×1.8m=360mm (left shift compensation) is set.

[0090] Lifting method execution: 1. Preload and calibration Start the center of gravity closed loop system: Longitudinal sensor detects ΔP 纵 =14kN(left end P 左1 =48 tons, right end P 右1 = 34 tons), the lateral sensor detects ΔP 横 =6kN (the load on the right lifting eye 5 is too high); Due to ΔP 纵 >10kN and ΔP 横 >5kN, first drive the hydraulic cylinder to move the main lifting eye 1 to the right to ΔP 纵=2.8kN (takes 40 seconds), then adjust the right side chain to make ΔP 横 =1.9kN (sprocket rotation θ=0.65°×6≈3.9°).

[0091] 2. Lifting the rotor in a confined space at a speed of 0.45m / min: The tilt sensor detects the rotor's forward tilt α = 1.8° (due to laminar airflow disturbance in the duct); Laser rangefinder displays rear end D min =130mm (<150mm); Triggering collision avoidance control: a) The lifting speed is reduced to 0.18m / min; b) Calculate the deviation correction speed v corr =0.05×1.8×(130-100)=2.7m / min; c) The overhead crane moves backward at 2.1 m / min (<v corr ), after 5 seconds α = 0.7° and D min =210mm, return to original speed.

[0092] 3. Stress relief disassembly After the rotor is in place: Remove the second shackle of fall chain 3: the tension sensor shows F = 1.8kN>1.5kN, release at 0.05m / min until F = 0.7kN, then remove; Dismantle the shaft neck lifting eye 6 shackle: a) Hydraulic cylinder piston rod retraction ΔL = 0.6 × √82 ≈ 5.4 mm (equipment weight 82 tons); b) After locking the T-slider, the F fluctuation value is ≤±0.2kN, and the shackle is removed at 0.01m / min; The overhead crane was vertically inched at a frequency of 0.5 Hz for 12 seconds to eliminate residual stress.

[0093] 4.Balance beam recovery The auxiliary hook's electromagnetic gripping module activated, laser positioning deviation was 1.5mm (<2mm), and the magnetic connector was attached at a distance of 12cm (adsorption force 12kN > 8kN). The main hook descended at 0.4m / min, and the auxiliary hook ascended at 0.35m / min. The main hook disengaged when the load ratio reached 1:9. The auxiliary hook transported the beam to the recovery rack, and the limiter triggered demagnetization.

[0094] The number of devices and processing scales described herein are intended to simplify the description of the present invention. Applications, modifications, and variations of the present invention will be readily apparent to those skilled in the art.

[0095] Although the embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the description and implementation methods. They can be fully applied to various fields suitable for the present invention. For those familiar with the art, additional modifications can be easily implemented. Therefore, without departing from the general concept defined by the claims and the scope of equivalents, the present invention is not limited to the specific details and embodiments shown and described herein.

Claims

1. Large equipment lifting device, characterized in that: include: The balance beam has a T-shaped guide groove along its top surface along its length, a T-shaped slider is slidably fitted on the T-shaped guide groove, and a main lifting lug is provided on the T-shaped slider. The first lifting point, the second lifting point, and the third lifting point are symmetrically provided at both ends of the balance beam; The hydraulic drive system is integrated into the balance beam and includes a hydraulic cylinder and a controller. The cylinder body of the hydraulic cylinder is fixed inside the balance beam, and the end of the piston rod is hinged to a T-shaped slider. A pair of first lifting assemblies are respectively provided at both ends of the balance beam, one end of the first lifting assembly is hinged to the corresponding first lifting point, and the other end is detachably connected to the first lifting ear of the corresponding equipment; A pair of second lifting assemblies are respectively provided at both ends of the balance beam, each comprising a lifting belt and an electric fall chain, one end of the lifting belt is connected to the corresponding second lifting point, and the other end is connected to the movable end of the electric fall chain, the fixed end of the electric fall chain is detachably connected to the corresponding third lifting point, and the lifting belt is slidably sleeved on the second lifting ear of the corresponding equipment; Center of gravity closed-loop control system, including: Two longitudinal pressure sensors are respectively arranged directly below the first hanging points at the left and right ends of the balance beam; Two lateral pressure sensors are respectively arranged on the root bearing surface of the second lifting lugs at the left and right ends of the equipment; The adaptive adjustment module integrated in the controller is configured to realize the following functions: obtaining the load value P detected by the longitudinal pressure sensor in real time 左1 With P 右1 ; Real-time acquisition of the load value P detected by the lateral pressure sensor 左2 With P 右2 ; Calculate the longitudinal load difference ΔP 纵 =|P 左1 -P 右1 |; Calculate the lateral load difference ΔP 横 =|P 左2 -P 右2 |; When ΔP 纵 >10kN and ΔP 横 When ≤5kN, control the hydraulic cylinder to extend to ΔP 纵 ≤3kN; when ΔP 横 >5kN and ΔP 纵 When ≤10kN, control the electric chain to adjust to ΔP 横 ≤2kN; when ΔP 纵 >10kN and ΔP 横 When >5kN, first control the hydraulic cylinder to move so that ΔP 纵 ≤3kN, then control the electric chain to adjust ΔP 横 ≤2kN.

2. The hoisting device according to claim 1, characterized in that: A sliding base is provided on the T-shaped slider, a main lifting lug is provided on the top of the sliding base, and the sliding base is hinged to the end of the piston rod of the hydraulic cylinder; The first lifting assembly includes a connecting plate and a pulling plate, one end of the connecting plate is hinged to the corresponding first lifting point via a first pin, the other end is hinged to one end of the pulling plate via a second pin, and the other end of the pulling plate is detachably connected to the first lifting ear of the corresponding equipment; One end of the sling is connected to the corresponding second lifting point through a first shackle, and the other end is connected to the movable end of the length-adjustable electric fall chain through a second shackle; The electric chain fall includes: a worm gear reducer, whose output shaft is connected to the sprocket; a servo motor directly connected to the reducer input shaft; and an encoder that provides real-time feedback on the sprocket rotation angle. The length L of the T-shaped guide groove must meet the following requirements: L ≥ the maximum stroke of the hydraulic cylinder + 2 × the installation length of the electric chain fall, and L ≥ 1500 mm. The lateral pressure sensor is a split structure and can be detachably mounted on the root plane of the second lifting lug through a magnetic clamp. The detection probe is in vertical contact with the bearing surface of the second lifting lug. The hydraulic drive system also includes a hydraulic pump station; The structure of the adaptive adjustment module is configured to achieve the following functions: when ΔP 纵 >10kN and ΔP 横 When ≤5kN, the adaptive adjustment module generates a hydraulic cylinder displacement instruction, driving the hydraulic pump station to make the piston rod continuously extend and retract in one direction until ΔP 纵 ≤3kN; when ΔP 横 >5kN and ΔP 纵 When ≤10kN, a chain fall adjustment instruction is generated according to the formula θ=0.65°·ΔP 横 Calculate the target rotation angle of the sprocket and drive the servo motor to make the sprocket rotation angle error ≤±0.5° until ΔP 横 ≤2kN; when ΔP 纵 >10kN and ΔP 横 When >5kN, first execute the hydraulic cylinder displacement command to make ΔP 纵 ≤3kN, then execute the chain-fall adjustment command to make ΔP 横 ≤2kN; The manual emergency mechanism of the electric chain fall includes: a manual crank interface mounted on the output shaft of the servo motor; a self-locking angle of the worm gear reducer ≤ 3°; The connection structure between the lifting belt and the second lifting ear of the equipment includes: a polyurethane wear-resistant layer with a thickness of 2-3mm lined on the lifting belt ring; and a hard alloy layer with a thickness of 0.5mm and a hardness of HRC55-60 built-up on the surface of the second lifting ear of the equipment.

3. The hoisting device according to claim 2, characterized in that: The maximum stroke of the hydraulic cylinder is 700-800 mm, and the length L of the T-shaped guide rail and the maximum stroke S of the hydraulic cylinder satisfy the following relationship: L = (1.5-1.8) × (S + 2 × L chain ), where L chain is the installation length of the electric fall chain, and L chain The value range is 150-250mm; the installation length L of the electric fall chain chain It refers to the reference installation distance from the fixed end to the movable end of the electric fall chain, measured when the electric fall chain is at its initial length.

4. The large equipment lifting device according to claim 2, characterized in that: The structure of the adaptive adjustment module is also configured to implement the following functions: 纵 ≤10kN and ΔP 横 When >4kN, do one of the following: If ΔP 横 ≤5kN, give priority to generating hydraulic cylinder displacement instructions, wait for ΔP 纵 When the load reaches ≤3kN, the chain-fall adjustment instruction will be generated; If ΔP 横 >5kN, synchronously generate hydraulic cylinder displacement command and chain fall adjustment command, and execute interlocking logic: when ΔP 纵 ≥ΔP 横 When ΔP 纵 <ΔP 横 When ΔP is reached, the displacement speed of the hydraulic cylinder takes the lower limit of 5 mm / s, and the rotation speed of the sprocket takes the upper limit of 0.8° / s; 纵 ≤3kN and ΔP 横 ≤2kN.

5. Large equipment hoisting method, characterized in that: The following steps are involved: S1. Pre-assembly of the balance beam on the ground: Reposition the main lifting lug to the center of the balance beam. Connect the fixed end of the electric fall chain to the third lifting point of the balance beam via the quick-release pin assembly. Pre-enter the center of gravity coordinates of the equipment into the controller according to the center of gravity coordinates marked on the equipment drawing. S2. Connect the lifting equipment to the equipment: Operate the overhead crane hook to hook into the main lifting lug and lift the balance beam to directly above the equipment. Install the first lifting assembly: Articulate the connecting plate to the first lifting points on the left and right ends of the balance beam via the first pin. Articulate one end of the pull plate to the connecting plate via the second pin. Connect the other end of the pull plate to the first lifting lug of the equipment via a shackle. Install the second lifting assembly: Connect one end of the sling to the second lifting point of the balance beam via the first shackle. Connect the other end of the sling to the movable end of the electric fall chain via the second shackle. Slide the middle end of the sling into the second lifting lug of the equipment. S3. Preload and center of gravity calibration: Start the center of gravity closed-loop control system and monitor the longitudinal load difference ΔP in real time 纵 and the lateral load difference ΔP 横 ; When ΔP 纵 >10kN and ΔP 横 When ≤5kN, the controller drives the hydraulic cylinder to move the main lifting lug until ΔP 纵 ≤3kN; when ΔP 横 >5kN and ΔP 纵 When ≤10kN, the controller is set to θ=0.65°·ΔP 横 Calculate the sprocket angle of the electric chain and drive the electric chain to adjust until ΔP 横 ≤2kN; if ΔP 纵 >10kN and ΔP 横 >5kN, first execute the hydraulic adjustment command to make ΔP 纵 ≤3kN, then execute the chain-fall adjustment command to make ΔP 横 ≤2kN; the center of gravity closed-loop control system updates ΔP every 200-500ms 纵 and ΔP 横 value, and the hydraulic cylinder displacement speed is limited to 10-15mm / s, and the sprocket rotation speed is limited to 0.8-1.2° / s; S4. Hoisting in height-restricted spaces: Lift the equipment at a speed of ≤0.5m / min. During the lifting process, maintain a clearance of ≥100mm between the bottom of the equipment and any obstacles. When the equipment is lifted to the installation height, move the overhead crane so that the deviation between the equipment axis and the foundation axis is ≤5mm. S5. Positioning and Disassembly: After the equipment is in place, remove the second shackle, release the quick-release pin assembly at the fixed end of the electric fall chain, and remove the fixed shackle and first pin at the equipment's first lifting lug. Among them, when the sling described in step S2 is inserted into the second lifting ear of the equipment, the lateral offset direction of the center of gravity is calculated according to the coordinates of the center of gravity of the equipment pre-input by the controller, and the pre-offset amount δ is set to 0.15~0.25 times the width of the equipment, and δ≤0.5×the length of the T-type guide rail groove. The offset direction is opposite to the lateral offset direction of the center of gravity of the equipment.

6. The large equipment hoisting method according to claim 5, characterized in that: In step S4, real-time attitude monitoring and active collision avoidance control are added: inclination sensors are installed at the four corners of the top of the device to monitor the device tilt angle α in real time; laser rangefinders are installed at the four corners of the bottom of the device to measure the minimum distance D from the bottom of the device to the obstacle in real time. min ; When the following conditions are met at the same time, the collision avoidance control is automatically triggered: The equipment tilt angle α≥2° and D min ≤150mm; or D min ≤120mm; Anti-collision control includes: immediately reducing the lifting speed to ≤0.2m / min; according to formula v corr =k·α·(D min -100) calculate the horizontal correction speed of the overhead crane, where k = 0.05 (m / min) / (°·mm); drive the overhead crane to move in the direction of decreasing the inclination, and the moving speed ≤ v corr , until α<1° or D min After >200mm, the original lifting speed will be restored.

7. The large equipment hoisting method according to claim 6, characterized in that: Add stress relief control in step S5: Install a tension sensor at the shackle connection of the first lifting lug of the equipment to monitor the shackle axial load F in real time. Its signal output end is connected to the controller; perform graded unloading during the disassembly process: When removing the second shackle, if F>1.5kN, control the electric chain to slowly release the load at a speed of 0.05m / min until F≤0.8kN, then remove the shackle; When removing the fixed shackle at the first lifting eye of the equipment, drive the hydraulic cylinder to retract the piston rod 5-8mm and lock the T-type slider at the same time to generate a reverse preload force to offset the gravity of the equipment; When the tension sensor detects that the F fluctuation value is ≤±0.3kN, the fixed shackle is removed at a speed of ≤0.02m / min; After disassembly is completed, the controller activates the vibration suppression mode and controls the overhead crane to move vertically at a frequency of 0.5Hz and an amplitude of ±0.5mm for 10-15 seconds to eliminate residual stress in the equipment.

8. The large equipment hoisting method according to claim 7, characterized in that: After step S5, add intelligent recovery control for the balance beam: integrate magnetic quick-release connectors at the third lifting points at both ends of the balance beam, and configure an electromagnetic grab module for the overhead crane auxiliary hook; execute the one-key recovery protocol: A1. After the device is in place, the controller sends a wireless command to activate the electromagnetic grabbing module; A2. The overhead crane's auxiliary hook moves horizontally at a speed of 0.3 m / s to the position directly above the balance beam, and the position deviation is ≤ 2 mm through laser positioning calibration. A3, magnetic quick-release connector automatically locks within a distance of 10-15cm, with an adsorption force of ≥8kN; A4. Synchronous release of the main hook and auxiliary hook loads: The main hook descends at a speed of 0.4m / min; the auxiliary hook ascends at a speed of 0.35m / min. Weight sensors installed on the main and auxiliary hooks monitor the load transfer rate in real time. When the load ratio of the main and auxiliary hooks reaches 1:9, the main hook is fully released. A5. The auxiliary hook lifts the balance beam to the recovery frame, and the magnetic joint is automatically demagnetized and released after contacting the safety limiter.

9. The large equipment hoisting method according to claim 8, characterized in that: During the load transfer process in step A4, dynamic balance compensation is added: a three-axis gyroscope is integrated inside the balance beam to monitor the beam's pitch angle γ and roll angle β in real time. When |γ| ≥ 1.0° or |β| ≥ 1.2°, the following synchronous compensation is performed: Start the hydraulic drive system and press the formula ΔL x =K·β·L b Calculate the lateral compensation, where K=0.15, L b is the balance beam length; Control the differential extension and contraction of the left and right hydraulic cylinders: left cylinder displacement + ΔL x / 2, right cylinder displacement -ΔL x / 2; At the same time, adjust the horizontal deviation correction speed of the overhead crane anti-collision system so that v corr An additional increment of Δv = 0.02·|γ| m / min was added until |γ| ≤ 0.1° and |β| ≤ 0.2°, and then the original load transfer speed was restored.

10. The large equipment hoisting method according to claim 9, characterized in that: During dynamic balance compensation, the visual assisted positioning system is activated simultaneously: wide-angle industrial cameras are installed at both ends of the balance beam to capture the position deviation between the second lifting lug of the equipment and the second lifting point of the balance beam in real time; When the image recognition shows that the lateral offset of the second lifting eye is ≥3mm during the differential extension and contraction of the hydraulic cylinder or the deviation correction of the overhead crane, or the laser rangefinder detects that the change rate of the distance between the equipment and the obstacle is greater than 5mm / s, the system automatically generates a dynamic compensation correction factor; The correction factors include: adding 0.2 times the visual offset to the hydraulic differential; increasing the overhead crane's correction speed to 1.3 times its value; Compensation continues until the image deviation is ≤0.5mm and the distance change rate is ≤1mm / s, and the real-time positioning enhanced view is superimposed on the controller interface.

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