Pipe-laying machine and diesel hybrid pipe-laying machine power control strategy

Abstract

A pipe-laying machine includes a frame, a plurality of ground-engaging members movably supporting the frame, a prime mover, and a boom assembly and a counterbalance assembly supported on the frame. The boom assembly includes a boom. The counterbalance assembly includes a counterweight movably supported on the frame to counterbalance the boom assembly. The counterweight includes a battery box including at least one battery. A control strategy is also disclosed.

Description

TECHNICAL FIELD

[0001] The present invention relates generally to pipe-laying machines, and more particularly to a counterweight arrangement and power control strategy for a pipe-laying machine. BACKGROUND

[0002] Pipe-laying machines are work machines used in pipe-laying operations in which the pipe-laying machine raises, lowers, and carries heavy pipe. Balance assemblies are disposed along opposite sides of the pipe-laying machine to balance the forces of loads lifted via opposing booms positioned along opposite sides of the pipe-laying machine. The balance assemblies typically include a counterweight that includes a plurality of steel plates. The balance assemblies further include a support structure that allows the counterweight to be articulated for movement relative to the machine frame in order to counteract the moment applied by the loads lifted by the booms.

[0003] Pipe-laying can be a lengthy process depending on other operations that occur before or after a length of pipe is positioned by the pipe-laying machine. During operation, the pipe-laying machine can spend as much as 75% of the operating time idle for operator comfort.

[0004] In U.S. Patent No. 8,857,635, a large crane is provided with a primary energy source and a secondary energy source including an energy storage unit that can be used to power the crane cabin air conditioning compressor. The secondary energy source can include a battery box that can be centrally disposed on the crane or as a base ballast or over- crane counterweight on a separate counterweight carriage. SUMMARY

[0005] In one aspect, a pipe-laying machine is described that includes a frame, a plurality of ground engaging members movably supporting the frame, a prime mover, and a boom assembly and a balance assembly supported on the frame. The boom assembly includes a boom. The balance assembly includes a counterweight movably supported on the frame to balance the boom assembly. The counterweight includes a battery box including at least one battery.

[0006] According to another aspect of the application, a pipe-laying machine is provided, the pipe-laying machine including a frame, a plurality of ground-engaging members movably supporting the frame, and a boom assembly and a counterbalance assembly supported on the frame. The boom assembly includes a boom. The counterbalance assembly includes a counterweight movably supported on the frame to counterbalance the boom assembly. The pipe-laying machine further includes a cab conditioning system, a first power source including an engine, a second power source including at least one battery, and a control system including at least one controller. The control system is configured to store a reference profile for the pipe-laying machine, the reference profile including a lower battery power threshold. The at least one controller is configured to access the reference profile, determine a power level of the at least one battery, and compare the power level of the at least one battery to the lower battery power threshold. If the power level of the at least one battery is not less than the lower battery power threshold, the at least one controller is configured to operate at least the cab conditioning system from the second power source, and if the power level of the at least one battery is less than the lower battery power threshold, the at least one controller is configured to start the engine to charge the at least one battery while operating at least the cab conditioning system.

[0007] In yet another aspect of the application, a method of powering a cab conditioning system in a hybrid pipe-laying machine is provided, the hybrid pipe-laying machine including a frame supporting a cab, a boom assembly, and a counterbalance assembly; the counterbalance assembly including a movably supported counterweight to counterbalance the boom assembly; a plurality of ground-engaging members movably supporting the frame; the pipe-laying machine including an ignition switch, the cab conditioning system, a first power source including an engine, and a second power source including at least one battery. The method includes determining a power level of the at least one battery, and comparing the power level of the at least one battery to a lower battery power threshold. The method further includes, if the power level of the at least one battery is not less than the lower battery power threshold, operating at least the cab conditioning system from the second power source, and, if the power level of the at least one battery is less than the lower battery power threshold, starting the engine to charge the at least one battery while operating at least the cab conditioning system from the at least one battery. BRIEF DESCRIPTION OF DRAWINGS

[0008] Figure 1 A front view of an exemplary pipe-laying machine according to one embodiment of the application is shown;

[0009] Figure 2 is Figure 1 a side view of the pipe-laying machine.

[0010] Figure 3 is Figure 1 and Figure 2 a front view of the pipe-laying machine, with the counterbalance assembly in an extended position.

[0011] Figure 4It is according to the teachings of the present invention for use in Figures 1 to 3 A schematic diagram of an exemplary power system operating in a pipe-laying machine.

[0012] Figure 5 It is shown that it is used for Figure 4 Exemplary power systems and Figures 1 to 3 A flowchart illustrating the operation of the hybrid power control system for the pipe-laying machine.

[0013] Figure 6 It is shown that it is used for Figure 4 Exemplary power systems and Figures 1 to 3 A flowchart illustrating the operation of the cab control system under the conditions of a pipe-laying machine. Detailed Implementation

[0014] This invention relates to a power system for a pipe-laying machine 10, a hybrid power control system for the pipe-laying machine 10, and a cab adjustment control system for such a pipe-laying machine 10. Figure 1 , Figure 2 and Figure 3 An exemplary pipe-laying machine 10 is shown. The pipe-laying machine 10 includes a frame 12 supported on a plurality of ground engagement members 14, 16 configured to advance the pipe-laying machine 10 along a surface. In the illustrated embodiment, for example, the ground engagement members 14, 16 are track portions 18, 20 rotatably mounted by a drive sprocket 22. The pipe-laying machine 10 further includes a prime mover. The prime mover can have any suitable design, such as a first power source 24, for example, an engine 26. In at least one embodiment, the engine 26 is a diesel engine. The ground engagement members 14, 16 can be coupled to the engine 26 via a power system 28.

[0015] The pipe-laying machine 10 further includes a cab 30, which may include one or more machine controllers 32 and a cab controller 34, which may control, for example, a machine ignition switch 35, electronic components 36, and a cab adjustment system 38, such as heating and air conditioning.

[0016] The pipe-laying machine 10 further includes a boom assembly 40 mounted to the frame 12. The boom assembly 40 includes a boom 42, such as a lattice boom. The boom assembly 40 may further include a pulley block 44 attached to the distal end 46 of the boom 42, and a hook winch 48. A cable 50 may be connected to the hook winch 48 and wound around the pulley block 44. The hook 52 may be suspended on the cable 50. Thus, a lifting load (e.g., a pipe) suspended by the hook 52 can be raised and lowered by winding and unwinding the cable 50 around the hook winch 48. The boom assembly 40 may also include a boom winch 54. A cable 56 may be connected to the boom winch 54 to the distal end 46 of the boom 42, thereby allowing the boom winch 54 to raise and lower the boom 42 by winding and unwinding the cable 56 around the boom winch 54. The hook winch 48 and the boom winch 54 can be any suitable type of rotary actuator known in the art, such as a hydraulic or electric motor.

[0017] The pipe-laying machine 10 may also include a balancing assembly 58 detachably connected to the frame 12. The balancing assembly 58 may include a counterweight 60, which is movably coupled to the frame 12 via a linkage assembly 62. The linkage assembly 62 may have any suitable design; for example, the linkage assembly 62 may be a four-bar or five-bar linkage. The linkage assembly 62 may be actuated in any suitable arrangement to move the counterweight 60 from... Figure 1 and Figure 2 The retraction position shown is moved to the position shown in the figure. Figure 3 The lever assembly 62 can be moved to the extended position shown, or to any position in between. For example, the lever assembly 62 can be hydraulically controlled, for example, by one or more hydraulic cylinders 64. During operation, the hydraulic cylinders 64 can be actuated to move the counterweight 60 between the extended and retracted positions. During operation of the boom assembly, the counterweight 60 can extend to balance the lifting load carried by the hook 52 by providing a counteracting torque that is opposite to the torque caused by the lifting load of the boom assembly 40. Each torque corresponds to each weight (lifting load or counterweight 60) acting at a horizontal distance between the weight and the center of gravity of the pipelaying machine. The horizontal distance between the counterweight 60 and the center of gravity of the pipelaying machine can be adjusted by an actuator, i.e., in the illustrated embodiment, for the hydraulic cylinders 64, to generate the desired torque that counteracts the various torques caused by the lifting load.

[0018] According to aspects of the invention, the prime mover may further include a second power source 70, which includes at least one battery 72 as an electrical energy source. Those skilled in the art will understand that the second power source 70 may include multiple batteries 72. In at least one embodiment, the battery 72 is disposed in a battery case 74 and positioned as a counterweight 60 of the balancing assembly 58, i.e., at least a portion of the counterweight 60. In at least one embodiment, at least one battery 72 is sealed and capable of rotating during operation of the pipe-laying machine 10 and movement of the balancing assembly 58 without leakage of the contents of the battery 72. In at least one embodiment, the battery case 74 is a protective, waterproof structure that resists environmental elements in which the pipe-laying machine typically operates. In at least one embodiment, the battery case is metallic.

[0019] At least one battery 72 is electrically connected to the pipe-laying machine 10 via a battery cable disposed within one or more protective conduits 76. Those skilled in the art will understand that the conduits 76 can be disconnected from the battery 72 and / or the pipe-laying machine 10 to facilitate replacement of the conduits 76 and / or the battery 72. The battery box 74 may additionally include a switch 78 accessible from the ground by an operator or maintenance personnel.

[0020] The first and second power sources 24 and 70 can be used as a hybrid power system 80. An exemplary hybrid power system 80 in... Figure 4 The diagram is schematically shown. The first power source 24 may be an engine 26, such as a diesel engine, which can be used to generate power that is supplied to the second power source 70, i.e., at least one battery 72, via a generator 82 and an inverter 84. The generator 82 and the inverter 84 can be operatively connected to the second power source 70 via multiple cables 86, 88, 90.

[0021] At least one battery 72 can be used to provide full machine functionality or to power selective operations of the pipelaying machine 10. For example, at least one battery 72 can be used to power the operation of the pipelaying machine 10, such as the cab adjustment system 38, and the operation of one or both of the hook winch 48 and the boom winch 54. At least one battery 72 can also be used to operate an electric drive system 92, which may include one or more electric motors 94, 96 dromotivably coupled to ground engagement members 14, 16. The electric motors 94, 96 may be operatively connected to drive sprockets 22, which drive track sections 18, 20. In an alternative embodiment including wheels (not shown), the electric motors may be used to drive the wheels. It is further understood that one or more additional electric motors may be provided to operate other components of the pipelaying machine 10, such as the winches 48, 54. Multiple cables 100, 102, 104 are provided to operatively connect at least one battery 72 to various machine operations.

[0022] The pipe-laying machine 10 can include various aspects of the pipe-laying machine 10, and these aspects can be controlled by the machine control system 106, such as... Figure 1 The arrows indicating machine-related aspects are shown in the diagram. The machine control system 106 may include electronic control modules or controllers, such as controller 108, which controls various aspects of the operation of the pipe-laying machine 10, including the hybrid power system 80. Reference configuration files for the pipe-laying machine 10 may be stored within or accessed by controller 108, or stored elsewhere within the machine control system 108.

[0023] Controller 108 may be an electronic controller that operates logically to perform operations, execute control algorithms, store and retrieve data, and perform other desired operations. Controller 108 may include or access memory, secondary storage devices, a processor, and any other components for running applications. Memory and secondary storage devices may be in the form of read-only memory (ROM) or random access memory (RAM) or integrated circuits accessible by controller 108. Various other circuits may be associated with controller 108, such as power supply circuits, signal conditioning circuits, driver circuits, and other types of circuits.

[0024] Controller 108 may be a single controller or may include more than one controller configured to control various functions and / or features of control system 106. The term "controller" is intended to be used in the broadest sense to include one or more controllers and / or microprocessors that may be associated with pipelaying machine 10 and may cooperate in controlling various functions and operations of pipelaying machine 10. The functions of controller 108 may be implemented in hardware and / or software without regard to functionality.

[0025] The pipe-laying machine 10 may be equipped with multiple machine sensors that provide (directly or indirectly) data indicating the operating characteristics of the pipe-laying machine 10. More specifically, the pipe-laying machine 10 may include at least one battery charge sensor 110, which indicates the current state of charge of at least one battery 72. The term "sensor" is intended to be used in its broadest sense to include one or more sensors and associated components that may be associated with the pipe-laying machine 10 and can cooperate to sense or identify the state of charge of at least one battery 72.

[0026] Industrial applicability

[0027] exist Figures 5 to 6 An exemplary flowchart illustrates an exemplary system and method according to the present invention. First, refer to... Figure 5The diagram illustrates a machine control system 106 according to the teachings of the present invention. In stage 501, the exemplary system is started when the machine ignition switch 35 is activated. In stage 502, at least one controller 108 accesses a reference profile of the pipe-laying machine 10. In stage 503, at least one controller 108 determines the power level of at least one battery 72 based on a battery power sensor 110. In stage 504, at least one controller 108 determines whether the power level of at least one battery 72 is greater than a lower battery power threshold. If the power level is greater than the lower battery power threshold, the mechanical functions of the pipe-laying machine 10 are operated from a second power source 70 (stage 505). This cycle of determining the power level of at least one battery 72 and comparing it to a lower battery threshold is repeated until the power level of at least one battery 72 drops below the lower battery power threshold.

[0028] When at least one controller 108 determines in stage 504 that the power level of at least one battery 72 has dropped below a lower battery power threshold, the engine 26 is operated to charge at least one battery 72 while providing full machine functionality (stage 506). In stage 507, the controller determines the power level of at least one battery 72 based on battery charge sensor 110. In stage 508, at least one controller 108 determines whether the power level of at least one battery 72 is less than a charging battery power threshold.

[0029] If, in stage 508, the power level of at least one battery 72 is less than the rechargeable battery power threshold, the engine continues to operate, causing the system to return to stage 506. Stages 507 and 508 are then repeated until the power level of at least one battery 72 is not less than the rechargeable battery power threshold.

[0030] If the power level in stage 508 is not less than the charging power threshold of the rechargeable battery, the machine function of the pipe-laying machine 10 is operated from the second power source 70, returning to stage 505. In stage 503, the cycle of determining the power level of at least one battery 72 and comparing it with the lower battery threshold (stage 504) is repeated until the power level of at least one battery 72 drops below the lower battery power threshold again, at which point the controller 108 restarts the engine 26 (stage 506).

[0031] When the pipelaying machine 10 is idling, this strategy can be used alternatively or additionally as a method of powering the cab adjustment system 38 to ensure operator comfort in the cab 30. (Reference) Figure 6This diagram illustrates a machine control system 106 that provides limited power to a pipe-laying machine, such as a cab adjustment system 38. In stage 601, the exemplary system is activated when the machine ignition switch 35 is turned on. In stage 602, at least one controller 108 accesses a reference profile for the pipe-laying machine 10. In stage 603, at least one controller 108 determines the power level of at least one battery 72 based on a battery power sensor 110. In stage 604, at least one controller 108 determines whether the power level of at least one battery 72 is greater than a lower battery power threshold. If the power level is greater than the lower battery threshold, the cab adjustment system 38 of the pipe-laying machine 10 is operated from a second power source 70 (stage 605). This cycle of determining the power level of at least one battery 72 and comparing it to a lower battery threshold is repeated until the power level of at least one battery 72 drops below the lower battery power threshold.

[0032] When at least one controller 108 determines in stage 604 that the power level of at least one battery 72 has dropped below a lower battery power threshold, controller 108 operates engine 26 to charge at least one battery 72, while simultaneously operating cab adjustment system 38 (stage 606). In stage 607, controller 108 determines the power level of at least one battery 72 based on battery charge sensor 110. In stage 608, at least one controller 108 determines whether the power level of at least one battery 72 is less than a charging battery power threshold.

[0033] If the power level of at least one battery 72 is less than the rechargeable battery power threshold (step 608), the engine 26 continues to operate, causing the system to return to step 606. Then stages 607 and 608 are repeated until the power level of at least one battery 72 is not less than the rechargeable battery power threshold.

[0034] If the power level of at least one battery 72 is not less than the charging battery power threshold in stage 608, the cab adjustment system 38 of the pipelaying machine 10 operates from the second power supply 70 and returns to stage 605. In stage 603, the cycle of determining the power level of at least one battery 72 and comparing it with the lower battery threshold (stage 604) is repeated until the power level of at least one battery 72 drops below the lower battery power threshold again, at which point the controller 108 restarts the engine 26 (stage 606).

[0035] Therefore, some embodiments of the present invention may be useful in the operation of the pipelaying machine 10 at the work site, especially when the pipelaying machine 10 is idling. Some embodiments can reduce fuel consumption.

[0036] While various aspects of the invention have been specifically shown and described with reference to the foregoing embodiments, those skilled in the art will understand that various additional embodiments can be conceived through modifications to the disclosed pipe-laying machines, systems, and methods without departing from the spirit and scope of the disclosure. These embodiments should be understood to fall within the scope of the invention as defined by the claims and any equivalents.

[0037] While the foregoing description provides examples of the disclosed systems and techniques, it is conceivable that other implementations of the invention may differ in detail from the foregoing examples. All references to the invention or examples thereof are intended to refer to the specific examples discussed herein and are not intended to imply any limitation on the scope of the invention in a more general sense. All distinguishing and derogatory language regarding certain features is intended to indicate a lack of preference for those features, but not to exclude them entirely from the scope of the invention, unless otherwise specified.

Claims

1. A pipe-laying machine, comprising: frame; Multiple ground-mounted components that can be movably supported by the frame; prime mover; A boom assembly supported on the frame, the boom assembly including a boom; A balancing assembly supported on the frame, the balancing assembly including a counterweight movably supported on the frame to balance the boom assembly, wherein the counterweight includes a battery box including at least one battery; The cab adjustment system and a control system including at least one controller, the control system being configured to store a reference profile of the pipelaying machine, the reference profile including a lower battery power threshold and a rechargeable battery power threshold, the rechargeable battery power threshold being greater than the lower battery power threshold, the at least one controller being further configured to: Access the reference configuration file; Determine the power level of the at least one battery; The power level of the at least one battery is compared with the lower battery power threshold; as well as If the power level of the at least one battery is less than the lower battery power threshold, then the first power supply is operated to charge the at least one battery until the power level of the at least one battery is not less than the rechargeable battery power threshold.

2. The pipe-laying machine according to claim 1, comprising at least a first power source and a second power source, wherein the first power source comprises an engine and the second power source comprises the at least one battery.

3. The pipe-laying machine according to claim 2, wherein, The controller is further configured to operate the second power source to supply power to at least the cab adjustment system if the power level of the at least one battery is not less than the lower battery power threshold.

4. The pipe-laying machine of claim 3, wherein the at least one controller is further configured to interrupt the operation of the first power supply when the power level of the at least one battery is at least equal to the power threshold of the rechargeable battery.

5. A pipe-laying machine, comprising: frame; Multiple ground-mounted components that can be movably supported by the frame; A boom assembly supported on the frame, the boom assembly including a boom; A balancing assembly supported on the frame, the balancing assembly including a counterweight movably supported on the frame to balance the boom assembly; Cab adjustment system; Including the engine's primary power source; A second power source including at least one battery; as well as A control system including at least one controller, the control system being configured to store a reference profile of the pipelaying machine, the reference profile including a lower battery power threshold and a rechargeable battery power threshold, the rechargeable battery power threshold being greater than the lower battery power threshold, the at least one controller being configured to: Access the reference configuration file, Determine the power level of the at least one battery. The power level of the at least one battery is compared with the lower battery power threshold. If the power level of the at least one battery is not less than the lower battery power threshold, then at least the cab adjustment system is operated from the second power source. If the power level of the at least one battery is less than the lower battery power threshold, the engine is started to charge the at least one battery while at least the cab adjustment system is operated, until the power level of the at least one battery is not less than the charging battery power threshold.

6. The pipe-laying machine according to claim 5, wherein, The at least one controller is further configured to: The power level of the at least one battery is determined when the engine is running. The power level of the at least one battery is compared with the power threshold of the rechargeable battery. If the power level of the at least one battery is equal to or greater than the charging battery power threshold, then the operation of the engine is interrupted and at least the cab adjustment system is operated from the second power source. If the power level of at least one battery is less than the charging battery power threshold, the engine continues to operate to charge the at least one battery.

7. The pipe-laying machine according to any one of claims 5 or 6, wherein the at least one controller is configured to operate the pipe-laying machine with all the functions from the second power source.

8. A method for providing power to a cab adjustment system in a hybrid pipe-laying machine including a frame supporting the cab, a boom assembly, and a balancing assembly, the balancing assembly including a movably supported counterweight to balance the boom assembly, a plurality of ground engagement members movably supporting the frame, an ignition switch, a cab adjustment system, a first power source including an engine, and a second power source including at least one battery, the method comprising: Access a reference configuration file stored in the control system, the reference configuration file including a lower battery power threshold and a rechargeable battery power threshold, the rechargeable battery power threshold being greater than the lower battery power threshold; Determine the power level of the at least one battery. The power level of the at least one battery is compared with the lower battery power threshold. If the power level of the at least one battery is not less than the lower battery power threshold, then at least the cab adjustment system is operated from the second power source. If the power level of the at least one battery is less than the lower battery power threshold, the engine is operated to charge the at least one battery while operating at least the cab adjustment system from the first power source.

9. The method of claim 8, further comprising: The power level of the at least one battery is determined during engine operation. The power level of the at least one battery is compared with the power threshold of the rechargeable battery. If the power level of the at least one battery is less than the power threshold of the charging battery, the engine continues to operate. If the power level of the at least one battery is not less than the power threshold of the charging battery, then the operation of the engine is interrupted and at least the cab adjustment system is operated from the second power source.

10. The method according to any one of claims 8 or 9, further comprising operating the pipe-laying machine with all the functions from the second power source.

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