Electric control system and electric control method for tower crane

Abstract

The invention provides an electric control system and an electric control method for a tower crane. The electric control system comprises a driving mechanism, a tower crane control module and a battery module, the tower crane control module is connected with the driving mechanism, and the tower crane control module carries out emergency treatment when a fault occurs; the battery module is arranged on the tower crane and connected with the tower crane control module, and the battery module is used for supplying power to the driving mechanism through the tower crane control module; wherein the battery module comprises an intelligent charging module, a battery management module and a battery cell; the intelligent charging module is used for charging the battery cell; the battery management module is used for detecting the cell operation state and controlling the charging process according to the cell operation state. Therefore, through the cooperative use of the battery module and the tower crane control module, the tower crane is safer and more reliable in the operation process, the action of the tower crane can be controlled in time in case of sudden power failure or failure, the safety of nearby operators is guaranteed, and the reliability and safety of the tower crane during operation are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of tower cranes, and in particular to an electric control system and an electric control method for a tower crane. Background Art

[0002] As a construction-type aerial work equipment, the working power supply of tower crane is provided by the construction site. However, in this link, there are the following problems.

[0003] First, the power supply at construction sites is usually temporary and unstable. Once there is a temporary power outage or the main switch trips suddenly, the tower crane will instantly lose power and thus lose effective control over the hoisted load. At this point, the hoist drum can only be braked by mechanical brakes or safety clamps. As a result, the system is subjected to a great impact force, which will cause serious damage to the wire rope and related mechanisms. Even more dangerous is that it may cause the heavy objects to lose control and fall from a high altitude, posing a huge threat to the life safety of the personnel and facilities on the construction work surface below, and the risk factor is extremely high.

[0004] Secondly, the power requirements of the power supply on the construction site are quite demanding. The larger the tonnage of the tower crane, the greater the installed power of its electric control system, and accordingly, the required power supply power also increases. If a separate power supply line is built for it or a temporary substation is built, the construction cost will be greatly increased, which will undoubtedly bring considerable economic pressure and construction difficulties to the construction party.

[0005] The three major mechanisms of tower cranes: lifting mechanism, slewing mechanism and luffing mechanism, all use a transmission method of three-phase asynchronous motor + reduction gearbox + drum. This transmission method has many troubling problems.

[0006] First of all, its appearance and volume are huge, which takes up a lot of space. For equipment working at high altitude, the high altitude space and configuration matching will be subject to many restrictions.

[0007] Secondly, the design cost is quite high. From the initial research and development to the actual production and manufacturing, each link requires a lot of capital and technical force, which undoubtedly increases the production cost and economic burden of the enterprise.

[0008] Furthermore, the repair and maintenance process is extremely cumbersome. Due to its complex structure and high safety and reliability requirements, professional maintenance personnel are required to spend a lot of time and energy to carefully inspect and maintain each component during repair and maintenance, which not only increases the difficulty of repair and maintenance, but also increases the corresponding cost.

[0009] In addition, the counterweight of the tower crane's balance arm is usually made of concrete, and the common concrete counterweight blocks weigh about 1-3 tons each. During the operation of the tower crane, as the position of the lifting arm changes, the position and weight of the counterweight are adjusted to ensure the overall stability of the tower crane and prevent the tower crane from overturning. However, the traditional configuration has the disadvantages of difficult weight accuracy control, relatively large volume, poor aesthetics, and long-term exposure to outdoor environments, which makes it susceptible to erosion by rain, moisture, etc. In cold areas, the freeze-thaw cycle in winter may cause damage to the internal structure of the concrete counterweight, reduce its strength and stability, and may cause cracks, peeling, etc., affecting its service life and safety performance.

[0010] During the lifting, slewing and luffing movements of the tower crane controller, failures may occur, posing a huge threat to the life safety and facilities of the personnel working on the building surface below. The risk factor is extremely high, making the tower crane operation process unreliable and with high safety risks. As a large-scale lifting equipment widely used in construction and other fields, tower cranes are special high-altitude equipment with extremely high safety concerns. All manufacturers are installing new technologies and new sensor designs to ensure the safety of tower crane operations. There are even a number of professional companies on the market that focus on developing electronic monitoring systems (commonly known as black boxes) for the safe operation of tower cranes. However, none of them started from the root of R&D and design, and they are "patch-up" designs.

[0011] Therefore, how to improve the reliability of tower crane operations and reduce safety risks is an urgent problem to be solved. Summary of the invention

[0012] The main purpose of the present invention is to provide an electric control system and an electric control method for a tower crane, so as to at least solve the problems of poor reliability and high safety risks in the process of temporary power supply operation of tower cranes in the prior art.

[0013] In order to achieve the above-mentioned object, the present invention provides an electric control system for a tower crane, comprising: a driving mechanism, a tower crane control module and a battery module; the driving mechanism is used to drive the tower crane to perform lifting, rotation and luffing actions; the tower crane control module is connected to the driving mechanism, and the tower crane control module is used to control the driving mechanism to perform actions and perform emergency processing when a fault occurs; the battery module is arranged on the tower crane and connected to the tower crane control module, and the battery module is used to supply power to the driving mechanism through the tower crane control module;

[0014] Among them, the battery module includes an intelligent charging module, a battery management module and a battery cell, the intelligent charging module is used to charge the battery cell; the battery management module is used to detect the operating status of the battery cell and control the charging process according to the operating status of the battery cell.

[0015] Furthermore, the battery module is arranged as a counterweight at the rear end of the tower crane balance arm.

[0016] Furthermore, the tower crane control module includes: an integrated drive inverter and a controller; the integrated drive inverter is connected to the drive mechanism, and the integrated drive inverter is used to provide a stable current to the drive mechanism; the controller is connected to the integrated drive inverter, and the controller is used to issue control instructions to the integrated drive inverter to control the drive mechanism to perform corresponding actions through the integrated drive inverter.

[0017] Furthermore, the integrated drive inverter includes: a lifting inverter, a slewing inverter and a variable amplitude inverter; the lifting inverter is used to provide a stable current for the driving mechanism to perform a lifting action; the slewing inverter is used to provide a stable current for the driving mechanism to perform a slewing action; the variable amplitude inverter is used to provide a stable current for the driving mechanism to perform a variable amplitude action;

[0018] Wherein, the controller uses two independent RS network interfaces to connect with the hoisting inverter, the slewing inverter and the amplitude variable inverter respectively.

[0019] Furthermore, the driving mechanism comprises: a three-phase permanent magnet synchronous electric drum and a synchronous motor; the three-phase permanent magnet synchronous electric drum is used to drive the lifting action mechanism, the rotating action mechanism and the luffing action mechanism of the tower crane to work; the synchronous motor is an embedded structure in the outer rotor permanent magnet;

[0020] Wherein, the synchronous motor is installed inside the three-phase permanent magnet synchronous electric drum to drive the three-phase permanent magnet synchronous electric drum to rotate.

[0021] Furthermore, the battery cell adopts a lithium iron phosphate battery.

[0022] Another aspect of the present invention further provides an electric control method for a tower crane, wherein the electric control method is applied to the electric control system of the present invention, and the electric control method comprises the following steps:

[0023] Installing a battery module on the tower crane and charging the battery module through an external power source;

[0024] The battery module supplies power to the driving mechanism of the tower crane through the tower crane control module;

[0025] The tower crane control module controls the driving mechanism to execute actions and performs emergency processing when a failure occurs.

[0026] Furthermore, the external power source charges the battery module including: starting charging when the power of the battery module is less than a preset minimum charging power threshold; and stopping charging when the power of the battery module is greater than a preset maximum charging power threshold.

[0027] Furthermore, installing the battery module on the tower crane comprises the following steps:

[0028] The counterweight weight of the battery module on the tower crane balance arm is determined by calculation according to the moment balance principle;

[0029] The battery module is installed on the tower crane balance arm according to the determined counterweight weight.

[0030] Furthermore, emergency treatment is performed when a fault occurs, including the following steps:

[0031] When the fault is detected as an electrical or mechanical fault, an alarm is issued and the corresponding action is stopped; or, when the fault is detected as a network fault, another network interface is immediately switched and the connection is reestablished.

[0032] The technical solution of the present invention is an electric control system for a tower crane, comprising a driving mechanism, a tower crane control module and a battery module; the driving mechanism is used to drive the tower crane to perform lifting, rotation and luffing actions; the tower crane control module is connected to the driving mechanism, the tower crane control module is used to control the driving mechanism to perform actions, and to perform emergency treatment when a fault occurs; the battery module is arranged on the tower crane and connected to the tower crane control module, the battery module is used to supply power to the driving mechanism through the tower crane control module; wherein the battery module comprises an intelligent charging module, a battery management module and a battery cell; the intelligent charging module is used to charge the battery cell; the battery management module is used to detect the operating state of the battery cell and control the charging process according to the operating state of the battery cell. Thus, through the coordinated use of the battery module and the tower crane control module, the tower crane is made safer and more reliable during operation, and in the event of a sudden power outage or a fault, the tower crane can be controlled in time to ensure the safety of nearby operators, thereby improving the reliability and safety of the tower crane during operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The drawings constituting a part of the present application are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0034] Figure 1 It is a schematic diagram of a structural block diagram of an electric control system which can be selected according to an embodiment of the present invention;

[0035] Figure 2 It is a flowchart of an optional electric control method according to an embodiment of the present invention.

[0036] Reference numerals:

[0037] 10. Driving mechanism; 11. Three-phase permanent magnet synchronous electric drum; 12. Synchronous motor; 20. Tower crane control module; 21. Integrated drive inverter; 211. Hoisting inverter; 212. Slewing inverter; 213. Luffing inverter; 22. Controller; 30. Battery module; 31. Intelligent charging module; 32. Battery management module; 33. Battery cell. DETAILED DESCRIPTION

[0038] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of the present application can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0039] like Figure 1 As shown, an electric control system for a tower crane includes a drive mechanism 10, a tower crane control module 20 and a battery module 30; the drive mechanism 10 is used to drive the tower crane to perform lifting, rotation and luffing actions; the tower crane control module 20 is connected to the drive mechanism 10, and the tower crane control module 20 is used to control the drive mechanism 10 to perform actions and perform emergency processing when a fault occurs; the battery module 30 is arranged on the tower crane and connected to the tower crane control module 20, and the battery module 30 is used to supply power to the drive mechanism 10 through the tower crane control module 20;

[0040] The battery module 30 includes an intelligent charging module 31 , a battery management module 32 and a battery cell 33 ; the intelligent charging module 31 is used to charge the battery cell 33 ; the battery management module 32 is used to detect the operating status of the battery cell 33 and control the charging process according to the operating status of the battery cell 33 .

[0041] Specifically, in a tower crane, the tower crane control module 20 controls the drive mechanism 10 to make the tower crane perform corresponding lifting, slewing and luffing actions. In the process of the tower crane control module 20 controlling the drive mechanism 10 to perform various actions, a network failure may occur, resulting in the failure of the command signal of the tower crane control module 20 to be timely and accurately transmitted to the drive mechanism 10, so that the tower crane cannot perform the expected action. In addition, when an electrical failure or a mechanical failure occurs during the tower crane's action, the tower crane control module 20 takes emergency measures to ensure the safety of workers near the tower crane.

[0042] The battery module 30 includes an intelligent charging module 31, a battery management module 32 and a battery cell 33. When the intelligent charging module 31 charges the battery cell 33, it adopts a charging method of constant current first and then constant voltage. In the constant current stage, the current remains relatively stable; when the battery voltage reaches a certain value, it switches to constant voltage charging, and the current gradually decreases. This charging method can not only avoid overcharging, but also improve the charging speed to a certain extent, and at the same time protect the battery cell 33. The battery management module 32 is provided with battery detection and battery balancing functions. Among them, the battery cell 33 is composed of a plurality of battery cell 33 monomers. The battery detection detects the voltage, current, temperature and other parameters of each battery cell 33 monomer in the battery pack, and detects the operating status and early warning of the battery cell 33 in real time; the battery balancing function is to judge whether there is a difference between the battery cell 33 monomers and the degree of the difference according to the detection result of the operating status of the battery cell 33. The active balancing method is adopted to accurately calculate the amount of energy transfer through the control algorithm to avoid damage or performance degradation of the battery monomer due to excessive balancing speed or excessive degree, thereby improving the battery power utilization rate and extending the life.

[0043] The tower crane is operated in an intermittent mode, wherein the charging voltage U1 is 24 hours for all-weather charging, and the charging current i1 from the external power supply to the battery module 30 can be calculated according to the following formula:

[0044]

[0045] In formula 1:

[0046] P1 is the electric control installed power of the tower crane;

[0047] M7 is the intermittent duty rate;

[0048] t1 is the daily shift working time;

[0049] The applicant found that under the conditions of the tower crane's electronic control installed power, intermittent working rate and daily shift working hours, the actual charging current value calculated according to formula (1) was compared with the total rated current value of the tower crane main cable selection formula. The calculated required charging current i1 was about 7 / 30 of the original installed power current, which solved the problem of increased design cost and great economic pressure caused by the thick power supply cable; and solved the construction difficulties caused by the large power supply of the power supply source.

[0050] The power source of the tower crane is provided by the battery module 30. The battery module 30 stores enough electricity for the expected working time, which can avoid sudden power outages during the operation of the tower crane, causing the tower crane to lose power supply instantly and lose effective control over the hoisted load. On the one hand, the lifting drum is braked by mechanical brakes or safety clamps, so that the entire tower crane is subjected to great impact force, causing relatively serious damage to the wire rope and related mechanisms. In addition, it can also avoid the possible loss of control of heavy objects and fall from high altitudes, posing a huge threat to the life safety of workers below and facilities.

[0051] When determining the capacity of the battery module 30, factors such as discharge efficiency need to be considered in practical applications. The discharge efficiency is affected by various factors such as the ambient temperature of the battery and the size of the discharge current. Generally, the discharge efficiency fluctuates around 85% under different conditions. The capacity C of the battery module 30 is calculated according to the following formula:

[0052]

[0053] In formula 2:

[0054] P1 is the electric control installed power of the tower crane;

[0055] t1 is the daily shift working time.

[0056] In general, the coordinated use of the battery module 30 and the tower crane control module 20 makes the tower crane safer and more reliable during operation, and solves the problem that a sudden power outage or failure may threaten the safety of nearby workers.

[0057] In a possible implementation, the battery module 30 is provided as a counterweight at the rear end of the tower crane balance arm.

[0058] Specifically, the tower crane balance arm is mainly used to balance the center of gravity of the tower crane itself to ensure the stability and safety of the tower crane. The boom is the main component used for cargo lifting. Tower cranes need to have good stability when lifting heavy objects at high altitudes. The main function of the counterweight is to ensure its stability by balancing the center of gravity of the crane. The battery module 30 is set at the rear end of the balance arm as a counterweight, which can effectively balance the torque generated by the crane during operation and prevent the crane from tilting or shaking due to the forward shift of the center of gravity, thereby improving the stability of the operation. The battery module 30 is used to provide electricity and serve as the counterweight of the tower crane, which solves the problems of power supply and stability of the tower crane, and eliminates the danger of falling objects from high altitudes caused by cracks and peeling of the original counterweight material, thereby improving its service life and safety performance.

[0059] In a possible implementation, the tower crane control module 20 includes: an integrated drive inverter 21 and a controller 22; the integrated drive inverter 21 is connected to the drive mechanism 10, and the integrated drive inverter 21 is used to provide a stable current to the drive mechanism 10; the controller 22 is connected to the integrated drive inverter 21, and the controller 22 is used to issue control instructions to the integrated drive inverter 21, so as to control the drive mechanism 10 to perform corresponding actions through the integrated drive inverter 21.

[0060] Specifically, the tower crane control module 20, as the core module of the tower crane, accurately controls the lifting, amplitude change, rotation and other actions of the tower crane, so that the tower crane can work accurately according to the instructions of the operator, has various safety limit control functions, and can detect the operating status of each system of the tower crane. The stable current provided by the integrated drive inverter 21 to the drive mechanism 10 can ensure the smooth operation of the drive mechanism 10 and improve the operating efficiency and reliability of the equipment. In addition, the controller 22 can accurately control the execution action of the drive mechanism 10 by issuing control instructions to the integrated drive inverter 21.

[0061] In a possible implementation, the integrated drive inverter 21 includes: a lifting inverter 211, a slewing inverter 212 and a variable amplitude inverter 213; the lifting inverter is used to provide a stable current for the driving mechanism 10 to perform a lifting action; the slewing inverter is used to provide a stable current for the driving mechanism 10 to perform a slewing action; the variable amplitude inverter is used to provide a stable current for the driving mechanism 10 to perform a variable amplitude action;

[0062] The controller 22 is connected to the lifting inverter 211 , the slewing inverter 212 and the amplitude variable inverter 213 respectively by two independent RS485 network interfaces.

[0063] Specifically, the hoisting inverter 211, the slewing inverter 212 and the luffing inverter 213 can provide more accurate and stable current output, ensuring that the tower crane can smoothly and accurately complete the action during the hoisting, slewing and luffing process, reducing vibration and impact. In addition, the controller 22 is connected to each inverter through two independent RS485 network interfaces, and this design enhances the reliability of communication. Even if one communication fails, another communication can be enabled to ensure that the tower crane can continue to work normally.

[0064] In a possible implementation, the driving mechanism 10 includes: a three-phase permanent magnet synchronous electric drum 11 and a synchronous motor 12; the three-phase permanent magnet synchronous electric drum 11 is used to drive the lifting action mechanism, the rotary action mechanism and the luffing action mechanism of the tower crane to work; the synchronous motor 12 is an embedded structure in the outer rotor permanent magnet;

[0065] The synchronous motor 12 is installed inside the three-phase permanent magnet synchronous electric drum 11 to drive the three-phase permanent magnet synchronous electric drum 11 to rotate.

[0066] Specifically, the synchronous motor 12 is designed as an embedded structure in the outer rotor permanent magnet to replace the drum, and the three-phase permanent magnet synchronous electric drum 11 driving mode is applied to the driving mechanism 10 to drive the tower crane to perform lifting, rotation and luffing actions, which has many advantages: First, the design cost is lower, and components such as reducers and couplings are omitted, reducing the number and complexity of parts, thereby reducing the overall design cost. Reducers and couplings are relatively expensive components in traditional drive systems, and their omission can significantly save costs; second, the processing and installation are convenient, and the simplified structure makes the processing process simpler, reducing the processing procedures and difficulty. Solve the pain points of the high-altitude layout of the tower crane design, and the overall volume will be smaller. In terms of installation, the reduction in the number of components makes the installation process simpler, reduces the probability of installation errors, and improves the speed and accuracy of installation. At the same time, it also reduces the demand for installation space, making the overall layout more compact; third, the later maintenance is easy, because the reduction of vulnerable parts such as reducers and couplings reduces the frequency and cost of maintenance. The reducer needs to regularly check the gear wear, add lubricating oil and other maintenance work, and the coupling also needs to check the tightness and wear of the connection, but these maintenance work can be avoided in the solution of this application; Fourth, the motor direct drive mechanism has a relatively simpler structure and fewer failure points, making maintenance and overhaul easier. When a problem occurs, it is easier to locate the fault and repair it, saving maintenance time and labor costs. In general, the solution in this application has great advantages for some application scenarios with high requirements for space, cost and maintenance, and can improve the reliability and economy of the system, achieve the purpose of energy saving and cost reduction, and improve performance. It is technologically innovative and industry-leading.

[0067] The synchronous motor 12 is designed as an embedded structure in the outer rotor permanent magnet to replace the winding drum, and is directly driven by the motor.

[0068] The design of the driving mechanism 10 is described by taking a 10t lifting mechanism as an example, and other tonnages can also be designed in other embodiments. The diameter of the double-folded groove on the drum surface of the drum outer rotor is 605mm, which can be adjusted according to actual conditions.

[0069] According to the tower crane hoisting requirements, the rated tension of a single rope is 25000N, and the reserved coefficient is considered during design;

[0070] Rated torque M = LxF = 25000x0.605÷2+0.014x5 = 9062.5Nm;

[0071] The weight of ￠14mm steel wire rope is 0.9kg / m, the rope capacity of the drum is 500m, the total weight of the steel wire rope is 450kg; the weight of the hook is 905kg;

[0072] The maximum tension of a single rope is F = mg = 25000 + 450 + 905 ÷ 4X10 = 28387.5N, taking into account the reserved coefficient;

[0073] Maximum torque M = LxF = 28387.5x0.605÷2+0.014x5 = 10290Nm, taking into account the reserved coefficient;

[0074] Through MATLAB software simulation and motor modeling data analysis, when the maximum torque of 9.4KNm is less than the design value of 10.29KNm, the power is 75.8KW and the power factor is 0.97; when the rated torque is 4.69KNm, the power is 37.9KW and the power factor is 0.97, which meets the design standards of tower cranes.

[0075] In a possible implementation, the battery cell 33 is a lithium iron phosphate battery.

[0076] Specifically, lithium iron phosphate batteries have a higher energy density and can store more electricity at the same weight and volume. This is crucial for equipment with high power requirements such as tower cranes, which can significantly improve their endurance and ensure a stable power supply during long-term operations.

[0077] The present invention further provides an electric control method, which is applied to the electric control system of the present invention, and the electric control method comprises the following steps:

[0078] S101, installing a battery module 30 on a tower crane and charging the battery module 30 through an external power source;

[0079] S102, the battery module 30 supplies power to the driving mechanism 10 of the tower crane through the tower crane control module 20;

[0080] S103, controlling the driving mechanism 10 to execute actions through the tower crane control module 20, and performing emergency processing when a failure occurs.

[0081] Specifically, a battery module 30 is installed on the tower crane. The battery module 30 serves as a power reserve unit for the entire tower crane. The battery module 30 is charged by an external power source to ensure that there is sufficient power in the battery module 30 for the tower crane to operate. The use of the battery module 30 can avoid the safety risks that may be caused by sudden power outages.

[0082] The battery module 30 serves as a power source for the tower crane, and supplies power to the driving mechanism 10 through the tower crane control module 20, so that the driving mechanism 10 drives the lifting, rotation and luffing actions.

[0083] At the same time, the tower crane control module 20 also has powerful data processing and communication capabilities, and can receive signals from sensors, operating panels and other components in real time, and accurately control and adjust the drive mechanism 10 according to these signals. When a fault occurs, appropriate emergency measures are taken to ensure the safety of the tower crane operation in the event of a fault.

[0084] In a possible implementation, the external power source charges the battery module 30 including:

[0085] When the power level of the battery module 30 is less than the preset minimum charging power threshold, charging begins;

[0086] When the power level of the battery module 30 is greater than the preset maximum charging power threshold, charging is stopped.

[0087] Specifically, by setting a preset minimum charging power threshold and a preset maximum charging power threshold, it is possible to ensure that the battery module 30 is charged when the power is moderate, thereby avoiding overcharging or over-discharging. Overcharging may cause excessive heat and gas to be generated inside the battery, damaging the battery structure and shortening the battery life; while over-discharging may cause the chemical substances inside the battery to crystallize, reducing the battery capacity and performance. Therefore, this charging control strategy helps to protect the battery module 30 and extend its service life.

[0088] In a possible implementation, installing the battery module 30 on a tower crane includes the following steps:

[0089] The counterweight weight of the battery module 30 on the tower crane balance arm is calculated and determined according to the moment balance principle;

[0090] The battery module 30 is installed on the tower crane balance arm according to the determined counterweight weight.

[0091] Specifically, according to the moment balance principle, the forward bending moment M under working condition is 工况 The backward bending moment M in the non-working state 非工况 Equivalent, expressed as:

[0092] M 工况 =M 非工况 (3)

[0093] M 工况 =G 1 ×S 1 +Q×S Q -G 2 ×S 2 -G 配 ×S 配 (4)

[0094] M 非工况 =G 配 ×S 配 +G 2 ×S 2 -G 1 ×S 1 (5)

[0095] In formula (4) and formula (5):

[0096] G 1 It is the deadweight load of the crane arm + the deadweight load of the trolley + the deadweight load of the hook + the deadweight load of the wire rope;

[0097] S 1 It is the distance between the center of gravity of the boom and the components attached to the boom and the center of rotation;

[0098] Q is the hanging load;

[0099] S Q is the distance between the load and the slewing center;

[0100] G 2 is the deadweight load of the balance arm;

[0101] S 2 is the distance between the center of gravity of the balance arm and the center of rotation;

[0102] G 配 is the weight of the counterweight;

[0103] S 配 is the distance between the counterweight and the center of rotation.

[0104] By combining formula (3), formula (4) and formula (5), we can calculate the corresponding counterweight weight under different arm lengths and reasonably configure the counterweight combination to achieve moment balance.

[0105] When the arm length is determined, the weight of the equipped battery module 30 is calculated, and the battery module 30 having the calculated counterweight weight is installed on the balance arm.

[0106] The power of the battery module 30 for replacing the counterweight must be sufficient for the normal operation of the tower crane for one working day, that is,

[0107] P1*M7*t1≤M*ρ (6)

[0108] In formula (6):

[0109] M is the mass of the battery module 30;

[0110] ρ is the mass density of the battery cell 33;

[0111] M7 is the intermittent duty rate;

[0112] t1 is the daily shift working time;

[0113] Taking the STC7025 tower crane model produced by Shaanxi Construction Machinery as an example, when the tower crane is in the full arm state of 70 meters, the counterweight is 23.5 tons and the volume is 9.79 cubic meters.

[0114] The installed power of the electric control system is 96KW, the working voltage is 380V, and it works 24 hours a day with a work and construction interval rate of 0.8. The energy density of the lithium iron phosphate battery is 110Wh / kg, and the mass of the battery module 30 is 16.7 tons, which is less than the original counterweight of 23.5 tons. Since the calculated weight of the battery module 30 is not greater than the counterweight required under the full arm length condition, the counterweight can be configured according to different arm lengths in the later stage to meet the balancing requirements, so it meets the design requirements. The overall stability of a tower crane depends on the position of its center of gravity. When replacing the counterweight, if the mass of the new counterweight, that is, the battery module 30, is equivalent to or lighter than the original counterweight, and its distribution is reasonable, the center of gravity position of the crane will not change significantly, thereby maintaining the overall mechanical balance.

[0115] In a possible implementation, emergency processing is performed when a fault occurs, including the following steps:

[0116] When the fault is detected as electrical or mechanical, an alarm is sounded and the corresponding action is stopped;

[0117] or,

[0118] When it is detected that the fault is a network fault, it immediately switches to another network interface and reestablishes the connection.

[0119] Specifically, when the electronic control system detects an electrical or mechanical fault, it will first trigger an alarm to alert operators in the form of sound and light to ensure that they can detect and take appropriate measures in time; at the same time as the alarm is issued, the system will automatically stop the actions related to the fault to prevent the fault from further expanding or causing more serious consequences, so as to protect the safety of equipment and personnel. By issuing an alarm in a timely manner and stopping the fault action, potential damage to equipment and personnel caused by electrical and mechanical faults can be effectively avoided.

[0120] When the system detects a network failure, it will immediately try to switch to another available network interface to ensure that the device can still maintain basic communication and control functions when a certain communication network fails. After switching the network interface, the system will try to re-establish the network connection to ensure that the device can continue to communicate and exchange data with other related devices. Among them, when the fault is detected as a network failure, it will immediately switch to another network interface and re-establish the connection. A special MODBUS RTU communication protocol is designed in the electronic control system to handle network failures and recovery, including node status monitoring and fault recovery mechanisms. The activity of the node is detected by regularly sending heartbeat packets. Once a node failure is detected, the backup path is immediately started or the connection is re-established. The polling control response cycle is controlled within 40ms to achieve "senseless" operation and ensure system stability and reliability.

[0121] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. An electric control system for a tower crane, characterized in that: include: A driving mechanism (10), the driving mechanism (10) being used to drive the tower crane to perform lifting, rotation and luffing actions; A tower crane control module (20), the tower crane control module (20) being connected to the driving mechanism (10), the tower crane control module (20) being used to control the driving mechanism (10) to perform actions and to perform emergency processing when a fault occurs; a battery module (30) arranged on the tower crane and connected to the tower crane control module (20), the battery module (30) being used to supply power to the driving mechanism (10) through the tower crane control module (20); The battery module (30) comprises an intelligent charging module (31), a battery management module (32) and a battery cell (33); the intelligent charging module (31) is used to charge the battery cell (33); and the battery management module (32) is used to detect the operating state of the battery cell (33) and control the charging process according to the operating state of the battery cell (33).

2. The electric control system for a tower crane according to claim 1, characterized in that: The battery module (30) is arranged as a counterweight at the rear end of the tower crane balance arm.

3. The electric control system for a tower crane according to claim 1, characterized in that: The tower crane control module (20) comprises: An integrated drive inverter (21) connected to the drive mechanism (10), the integrated drive inverter (21) being used to provide a stable current to the drive mechanism (10); A controller (22) is connected to the integrated drive inverter (21), and the controller (22) is used to issue a control instruction to the integrated drive inverter (21), so as to control the drive mechanism (10) to perform a corresponding action through the integrated drive inverter (21).

4. The electric control system for a tower crane according to claim 3, characterized in that: The integrated drive inverter (21) comprises: A lifting inverter (211) is used to provide a stable current for the driving mechanism (10) to perform a lifting action; A rotary inverter (212) for providing a stable current for the driving mechanism (10) to perform a rotary action; A variable amplitude inverter (213), used for providing a stable current for the driving mechanism (10) to perform a variable amplitude action; The controller (22) is connected to the hoisting inverter (211), the slewing inverter (212) and the amplitude variable inverter (213) respectively using two independent RS485 network interfaces.

5. The electric control system for a tower crane according to claim 1, characterized in that: The driving mechanism (10) comprises: A three-phase permanent magnet synchronous electric drum (11), wherein the three-phase permanent magnet synchronous electric drum (11) is used to drive the lifting action mechanism, the slewing action mechanism and the luffing action mechanism of the tower crane to operate; A synchronous motor (12), wherein the synchronous motor (12) is an embedded structure in an outer rotor permanent magnet; The synchronous motor (12) is installed inside the three-phase permanent magnet synchronous electric roller (11) to drive the three-phase permanent magnet synchronous electric roller (11) to rotate.

6. The electric control system for a tower crane according to claim 1, characterized in that: The battery cell (33) is a lithium iron phosphate battery.

7. An electric control method for a tower crane, characterized in that: The electric control method is applied to the electric control system according to any one of claims 1 to 6, and the electric control method comprises the following steps: Installing a battery module (30) on the tower crane and charging the battery module (30) via an external power source; The battery module (30) supplies power to the driving mechanism (10) of the tower crane through the tower crane control module (20); The tower crane control module (20) controls the driving mechanism (10) to execute actions, and performs emergency processing when a failure occurs.

8. The electric control method for a tower crane according to claim 7, characterized in that: The external power source charging the battery module (30) comprises: When the power level of the battery module (30) is less than a preset minimum charging power level threshold, charging begins; When the power level of the battery module (30) is greater than a preset maximum charging power threshold, charging is stopped.

9. According to the electric control method for a tower crane as claimed in claim 7, installing the battery module (30) on the tower crane comprises the following steps: Calculating and determining the counterweight weight of the battery module (30) on the tower crane balance arm according to the moment balance principle; The battery module (30) is installed on the tower crane balance arm according to the determined counterweight weight.

10. The electric control method for a tower crane according to claim 7, wherein emergency treatment is performed when a fault occurs, comprising the following steps: When the fault is detected as electrical or mechanical, an alarm is sounded and the corresponding action is stopped; or, When it is detected that the fault is a network fault, it immediately switches to another network interface and reestablishes the connection.

Images